Packing automation success is all in the planning. Embarking on a mission to reconfigure its fresh-produce packing hall at Thrapston, the Morrisons Centre of Excellence - which prepares and delivers 130 million packs of fruit every year to 82 stores - has succeeded in its automation vision and ambition.
British automation company Brillopak supported Thrapston at every phase of the five-year programme. In total, they installed 11 fully integrated fresh-produce packing lines comprising around 40 machines, with equipment and capital investments split across three defined phases.
To support these apple-packing lines and eliminate any potential bottlenecks, two Crate DESTAKers, five bale arm closers and five double stackers for palletising were also introduced. The result was five integrated packing lines that maintained a consistent packing pace, each feeding out onto the main track to an existing palletising system.
Upscaling on 11 lines
Applying the best practice gained from phases one and two, in 2021 Thrapston completed its full-scale automation transformation with the roll out of six new linear packing lines. Handling a range of flow-wrapped and tray-sealed fresh produce, including pears, tomatoes, apricots, blueberries and grapes, Brillopak delivered a further five UniPAKers, one PAKstation, six bale arm closers, two Crate DESTAKers and six double stackers.
The smoother and gentler handling of fresh produce has been proven to reduce complaints by over 30 percent and almost instantly, reports the Head of Operations.
With all five fresh produce sites having end-to-end Brillopak machinery, a side-line benefit is how much the manufacturer has been able to streamline its stockholding of spares and components. “Dealing with one automation provider formed part of our produce directive. From a maintenance and ongoing service perspective, dealing with one or two machinery suppliers, versus liaising with multiple contacts is evidentially more straightforward. Being able to pre-plan projects and roll automation platforms out in phases as part of a wider, aligned plan certainly helps to mitigate investment risks,” ends Matt.
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For more information:
https://www.brillopak.co.uk