Small But Perfect Packs for S&B Herba Foods

UP Mini-001The Spanish owned rice milling company S&B Herba Foods have two UK processing sites both capable of milling, processing and packing a variety of rice types for the UK and overseas markets.

Their central site located in Fulbourne, Cambridgeshire processes up to 300 tonnes per day, the majority of which is packed into 10+Kg bags.  Packing of rice into 10-20Kg bags is currently done using an Umbra Packaging UP1000 automated packing and palletisation line.

Recent trends have seen an increase in demand for smaller pack sizes, S&B Herba Foods therefore made the decision in 2014 to look into adding a second packing line to operate alongside their existing UP1000 to produce pack sizes from 1Kg to 10Kg..

Over the past year S&B Herba Foods have investigated currently available machines capable of handling a wide variety of pre-made small size bags including; gusseted, zip lock and doypack.

CJ Waterhouse Company, acting as the UK agent for Umbra Packaging since January 2014 have been closely involved with the project since its onset.  During the tender process CJ Waterhouse have provided local engineering and commercial support to S&B Herba and have helped with the demonstration of Umbra’s capabilities including overseas visits to their manufacture facility in Perugia, Italy.

S&B Herba Foods have now made the decision to purchase an Umbra packaging UP Mini packing line and UPR palletisation line.  The machine will provide automated packing of rice into a variety of bag types from 1-10Kg with both heat sealing and stitching closure systems at speeds of up to 2000 bags per hour.

The decision to purchase the Umbra machine over its competitors was made not only due to the performance of the UP Mini and the customers knowledge of the UP1000 model but also because of the local engineering support offered by CJ Waterhouse Company both during the purchase procedure and for ongoing service and maintenance works.

In addition to their assistance in the supply of the Umbra packaging line CJ Waterhouse have also been awarded the contract to design, supply and install the material feed system required for the new packing line.

The existing system feeds rice to the downstream equipment from 8 internal and 3 external silos via a series of conveyors, elevators and routing valves.  The new feed system will permit the simultaneous routing of rice to both packing lines using a combination of new and existing conveying equipment.

Both the Feed system and packing lines are currently at design phase with scheduled delivery to S&B Herba Foods at the end of 2015 and start up in January 2016.

For information on materials handling, weighing and process control systems offered by CJ Waterhouse  or Umbra Packaging’s range of equipment please do not hesitate to contact us.

Tel: 01636 610792   –   Email: sales@cjwaterhouse.co.uk   –   Web: www.cjwaterhouse.co.uk

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CJ Waterhouse Complete Mixer Feed System Installation at TARRC

C J Waterhouse company have just completed the installation of a new automated mixer feed system for TARRC’s rubber compound research facility in Hertfordshire.  The system is designed to permit the offline weighing of compound batches and automated introduction into the mixer.

The batch ingredients are loaded into a transfer container which is then electronically tagged and transferred to the mixer.  When the transfer container arrives at the mixer the electronic (RF) tag is read and the operator is prompted to place the ingredients in the respective feed stations prior to commencing the mix sequence.  From this point the mixer can be operated manually using the SCADA or panel controls or put into automatic mode which will inject the ingredients and run through the mix sequence in accordance with the pre-specified recipe.

The weighing sequence, recipe handling and production scheduling is provided by our KS-Series production control software operating upon a Windows 8 platform and physical plant control is via a Mitsubishi Q-Series PLC

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3rd Generation Smart Cart Minor Ingredients System

 

CJ waterhouse company have recently completed the installation of their third generation of Smart Cart systems at a UK custom compounders.

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Introduction
The semi-automatic and subsequent fully automatic minor ingredient systems were first developed over 10 years ago to overcome the negative constraints associated with more traditional systems where feeders are positioned around a static central weigh vessel. Such systems can suffer from lower accuracy, contamination, slow throughput and limited or no expansion possibilities.

Smart Cart Philosophy
The Smart Cart overcomes these issues by moving individual weigh carriages with pre-loaded receptacles (bag, bucket etc.) to the feeder stations around a monorail track. In this way the raw ingredients are weighed directly into the container on the carriage from the feed station therefore eliminating cross contamination.

Each carriage incorporated a high accuracy force motion platform scale to give typical weighing accuracies on minor ingredients of +/- 3g or better. As the smart cart carriages run upon a continuous monorail track numerous carriages can be added to increase overall throughput.  This system can also reduce / eliminate costly downtime due to weigher malfunctions as each weigh carriage can be simply removed from the track for maintenance or repairs.  The remaining carriages will then continue the weighing operations or an additional spare carriage can be added to maintain the same throughput.

It is also possible due to the unique philosophy of the Smart cart to incorporate additional feed stations and track extensions at a later date if expansion should be required.

The fully automatic version of the Smart Cart manufactures bags on-line before loading them onto the carriage clamp system. The weigh carriage then proceeds around the track system collecting the required ingredients in accordance with the pre-specified recipe.  On completion of the batch the bag is printed with a barcode or batch information before being sealed and ejected onto the downstream accumulation system.  Semi & fully automatic systems for bucket, container and bulk IBC can also be supplied although the latter would normally be located upon a linear track.

System Developments
The Smart Cart is now into its 3rd generation (G3), previous developments from G1 to G2 have included; increased speed / throughput, packet separation and dosing systems, variable bag length and control / automation improvements.

CJ waterhouse Co Ltd have now completed the installation of the G3 version of the Smart Cart for supply to the UK custom compounding company Berwin Polymer processing Group in Lydney. Berwin’s Manchester plant first introduced the prototype semi-automatic system in 2002 and upgraded to the fully automatic system in 2004.  The automatic system has now been in operation for over 10 years.  Following Berwin’s recent expansion to the additional site in Lydney they are now looking to increase their minor ingredients output at the new site by the acquisition of a second Smart cart System.

The Smart cart G3 has two main technological advancements over the previous version. The first being the use of wireless communications between the carriages and the main PLC control panel.  A Mitsubishi Bluetooth system will be utilised to send / receive recipe and data information to and from the carriages.  Previous versions used a fixed copper conductor running around the track perimeter and pickup points on the carriages.  The bus conductor system is still utilised for carriage power distribution.

The second improvement is the addition of a radio frequency tag (RFT) positioning system. The G2 Smart Cart utilised a specific pattern of proximity sensors to identify each individual feeder station.  The carriage would stop at the required feeder station and look for a specific layout of sensor activation to check its position before commencing material dosing.  The G3 version weigh carriages now have RFT readers on-board and each feeder station has a programmable RFT fitted.  When the carriage stops at the feeder station it reads the identification tag to confirm the correct location.  This system is less susceptible to positional errors and reduces complexity and installation costs.

In summary the Smart cart provides a fully automated minor ingredients weighing system with the following features:

High Accuracy
High Throughput
Contamination Free
Expandable & Configurable
Full data logging & batch report
Automatic scheduling

 

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CJW takes on UK agency for Comav Italy – Industrial valves & automated sack emptying

C J Waterhouse have been appointed as the UK agent / partner company for Comav Srl.  Comav manufacture a range of industrial valves including, slide, rotary and divertor.  In addition to their valves Comav also manufacture a range of materials handling equipment including automated sack emptying and de-palletisation systems together with bailing presses and other bespoke solutions.

For more information on Comav’s product range please visit www.comav-srl.co or contact CJ Waterhouse on +44(0) 1636 610792.

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CJW contracted to supply Control System for TARRC

CJ Waterhouse company limited, in conjunction with Carters of Rochdale are contracted to supply a new control system and semi automatic batch weighing system for TARRC’s rubber research production facility in Hertfordshire.

The system will comprise of a new 50L internal mixer with semi automatic feed of powders and liquids.  The control and recipe handling system will utilise CJ Waterhouse’s Ks series production control software and Mitsubishi PLC and SCADA system.

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CJ Waterhouse form UK partnership with Umbra Packaging

Following the recent completion of a large animal feed plant in Belgium which incorporated the entire manufacture facility from raw materials in to packaged goods out. CJ Waterhouse have formed a working partnership with the Italian engineering company Umbra Packaging.  Umbra supply high speed packaging and palletisation solutions for dry powder and granule materials.

CJ Waterhouse provide Umbra’s UK clients with a local pre-sales support, technical after sales service including installation, commissioning, maintenance and service contracts.

For more information on the Umbra range of packaging systems please do not hesitate to contact us or visit Umbra at www.umbrapackaging.it

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