The Challenge
A leading snack food manufacturer engaged Elmleigh to upgrade a process line, aiming to improve production efficiency and hygiene through a bespoke conveyor system integrated with existing infrastructure.
Teams Involved
The Solution
The project commenced with a two-day 3D site scan and data processing. Existing point cloud data was reviewed to ensure design compatibility with legacy systems. The final design included 157 metres of stainless-steel trough conveyors, customised to product line width. A central tracking strip eliminated the need for automatic tracking, while stainless steel covers and under guards with gas struts provided dust containment and easy access for cleaning.
Hygiene & Maintenance Features
Drive ends were equipped with wrap-around rollers, scrapers, and removable trays. Standardised drives featured safety lanyards and isolators. All conveyors were inverter-controlled and integrated into a new control system.
Structural Adaptations
- Area 1: Floor- and wall-mounted L-frames
- Area 2: Suspended conveyors using existing steelwork
- Platforms: Two powder-coated mild steel platforms (9000×1200mm and 1000×1000mm) with galvanised Key Clamp handrails and ladders, compliant with BS EN 1090
A custom control panel was built using a Rittal VX25 stainless steel enclosure with copper earthing bar. It housed an Allen Bradley 5069-L320ERS2 Safety PLC and a 10" PanelView Plus 7 HMI for system control and visualisation. Connectivity was provided by a Hirschmann GECKO 8TX/2SFP Ethernet switch, with cooling via a Rittal 550m³/h fan. Additional features included 24VDC surge protection, illuminated pushbuttons, and a RAG beacon stack with integrated siren.
Following approval of the Functional Design Specification, PLC and HMI software were developed to manage decentralised emergency stops and inverter interlocking. The HMI provided full system visualisation, alarm management, device status, and manual controls. A digital I/O handshake enabled seamless integration with upstream/downstream systems.
The existing bagging and packing system were dismantled and relocated. Wiring was disconnected and coiled for reuse per a detailed schedule. Equipment including capping, shrink wrapping, and case sealing machines were removed intact. Conveyors and turntables were electrically disconnected for relocation.
Damaged cabling around the bagging machine was replaced with double-insulated multicore cabling. The system was reinstalled using existing containment and wiring, and the main panel reconnected as per the schedule.
Find out how Elmleigh can help
Elmleigh specialises in delivering engineered solutions tailored to the unique requirements of each project. From infrastructure upgrades and new facility developments to complex electrical installations, our multidisciplinary teams provide end-to-end support across design, manufacture, integration, and commissioning.
For technical consultation or to discuss your next project, please contact Elmleigh via our contact page or call us on 01455 847045. We’re here to help.
[22337]