Summit Systems Create Innovative Material Handling System

7th October 2010

Source: Summit Systems Ltd

Summit Systems Create Innovative Material Handling System

When John Ambler, Manufacturing Manager at Amcor Flexibles; one of the world’s largest suppliers of flexible packaging to many of the UK’s leading brands and retailers, was given the go ahead to create a production centre of excellence at his Ilkeston site, his goal was to satisfy both the need for improved efficiency and operator convenience. He needed to reduce material wastage, reduce labour costs and down-time. His aim was to utilise the latest technology to feed material from external silos and additive/master-batch bins to 5 x 3 layer co-extrusion lines and 1 single layer extrusion line. It was necessary for the plant to run 24/7 – 355 days a year in quantities with annual volumes in excess of 18,000 tonnes. The system had to be 100% reliable with no breakdowns and would be delivered to strict timetables and within budget.

Awarding the project to Summit Systems was an easy decision for Amcor. No other supplier came close to offering the solution which came from Summit Systems and John Ambler says “After the original concept came together I kept throwing obstacles into the mix and every time Summit came back with a solution.”

The system provided by Summit comprises 16 customised Material Storage Bins with cable holders, exactly as required thanks to Summit’s in-house fabrication facility. Customised material selection tables for mounting of material loaders and the latest automatic distribution tables with not 8 inlet/outlet pipes; as is available in standard form, but Summit produced them with 20 pipes as a bespoke solution. Amcor are an international Company and they are confident that this is a unique configuration in the UK and probably in Europe.

The positioning of this fully enclosed system on a mezzanine with the easy to use control panels on the lower floor has resulted in occupational health benefits, in addition to huge production improvements. Amcor now have a cleaner operation with no material wastage. They complete job changes in 5 minutes instead of one hour and they have cut the amount of time that operators spend using stairs to access higher warmer environments by 95%.

Summit Systems are additionally proud to say that this project was delivered on time, on budget and has not failed since it was installed.

Steve Wallis, Production Manager for Amcor is blunt in his praise “Our operators are the biggest critics. When they are asking for the Summit equipment in all other areas of the operation you know you are doing something right”

Mark Williams, Engineering Manager at Amcor comments “The combined effort of our team, Summit Systems and their suppliers has culminated in a system that has not let us down and is 100% reliable. The only time this system is not operational is during planned maintenance.”

The last word goes to John Ambler “I believe this is a unique installation. Previously we had been told by other suppliers that this was not possible in this form. But Summit and their suppliers worked together to provide new designs which achieve all the criteria I had wanted to address. I just wish I had more money in the budget to provide this system across my operation right now. Visitors from other areas of the group covet this system. I never tire of showing it off. It certainly has a very big wow factor and backs this up with impeccable performance”.

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