Greenvale capitalise on robot’s flexibility

The robot systems, two each at Greenvale’s Cambridgeshire and Berwickshire sites, were designed and supplied by food automation specialists Abar Automation. A strategic partner of FANUC Robotics UK Ltd, Abar Automation has supported the systems over their lifetime and managed the re-engineering on each occasion as required.

Each Abar DL-16 Container Loading Cell is the same and currently picking and placing pre-pack 2.5 Kg and 5 Kg bags of potatoes into Merchandisable Units (MU’s) at 60 bags per minute. Originally the systems had been designed to handle 30 bags per minute from a twisted tape bagging machine but improved packaging and capacity demands have seen this increase.

Rob Phillips, Operations Manager, Greenvale, Explains, “Since the robots were initially installed the systems have been moved and upgraded at least three times to accommodate different packaging formats. If we’d had a pick and place machine on a conveyor system the cost of re-engineering, where possible, would have been significantly higher.

“We do use collation systems here at Greenvale but one of the important considerations with the initial justification was the flexibility of robots. If the packaging format changes, or the retailer’s requirement changes we don’t have to scrap the whole system.”

Greenvale’s Cambridgeshire site has a production capacity of 2,400 tons per week – through implementing Lean practices and investment this capacity is equivalent to what three plants would be operating at ten years ago. Flexibility remains a core importance in justification of plant but equally important is the amount of space taken up, or available, relative to an increase in production.

“The Abar robot cells do have a very small footprint and this is an important criteria for us when deciding on automation – space is limited and costly and the robots have proved successful in achieving this objective. Looking to future systems we are aware of next generation case packing but we expect a small footprint and high speeds,” continues Rob.

On the issue of operation and maintenance of automation equipment at Greenvale, Rob Phillips explains that he has no issues here, “The robots just don’t present a problem – I believe there is even a case for stating that sometimes you can over service equipment with negative results – the FANUC Robots have been completely reliable with just one service a year.

“Our systems work because they are well engineered – I believe that 90% of success lies in programming and designing the handling/pick-up solution. Abar Automation developed new gripper and input conveyor solutions for us each time we had an upgrade and I believe this is what makes the systems work so well.”

Operating 2 shifts a day throughout the year means that system failure is not an option for Greenvale. Rob Phillips proudly quotes a service uptime of 99.98% and working close to a target of 99.99%. His emphasis to maintain these levels is to start off using well proven equipment and to ensure integration is competently undertaken.