The Challenge
A Long-Standing client approached us with an Intriguing job that our team had previous experience working with. The challenge in question was to remove their existing Conveyor system and install an updated model that fits the company’s standards, providing much-needed Automation to the system. All whilst ensuring our clients had Zero downtime within their Production capabilities and creating additional floor space for future upgrades to their systems.
The Teams
The Solution
Elmleigh was approached by the client because of our existing relations. The client initially approached us to assist with the initial Strip-out because we had provided support on the original line installation back in 2019. The installation, carried out during the COVID-19 pandemic, was intended to support the recent surge in E-commerce.
The task at hand had the team strip out the existing system in phases, which were outdated to the clients’ current standards. The line in question had Limited Automation and entirely manual decision points.
Our team took a Calculated approach, splitting the task into three phases, each phase corresponding to a certain segment of the conveyor system. From right to left, the phases began with the team stripping out the existing line along with any subsequent control panels.
The new system was then installed and integrated into the legacy line, creating a Hybrid line of the two different Systems to enable the target of Zero downtime. Six new Control Panels were commissioned, consisting of two large multi-bay main enclosure panels boasting a full Siemens control system, HMI, PLC and Inverters. This was also then replicated within the Four Remote Panels, installed at each section of induct, housing cabling for Sensors, safety Pull Cords and Inverter-Driven motors. Consequently, this decreased the cabling being installed directly into the main control panels.
During the phases of strip-out and installation, the existing control panels were Modified to support the initial Hybridisation of the two separate systems to the full Integration of the new system. External safety circuits were Hard-Wired to ensure the two systems would work in tandem, along with the old legacy line being stripped out.
The Outcome
Thanks to our Project Management team’s capabilities and previous knowledge of working on a task with similar parameters, our engineers completed both phases one and two within the set time scale. Phase three is still ongoing and is set to be completed in late Q3 2024. The Upgrade to the system has provided improved Functionality and ease of Operation for the client, with new Banded Rollers, Herringbone Sections for centralising parcels, Operator Interfaces, and new Maintenance-Friendly Control Panels manufactured within our Workshop. This upgrade to the client’s system not only satisfies conformity to their current Automation standards but has enabled integration to third-party Scanning and Automation sortation solutions.
Find out how Elmleigh can help
If your Food & Drink or Parcel Sortation business needs a similar service with a speedy supply time while delivering the highest-quality solution for your requirements.
Enquire now by filling out the form on our contact page. Alternatively, you can contact us at 01455 847045. We are open to any and all questions you might have about our services and how we at Elmleigh can help you.
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