Engineering Services

Design & Consultancy

With our team of experienced design engineers we can offer our customers a variety of engineering design services from simple drafting to bespoke system research, design development and prototype manufacture.

Our design services are offered from in-house resources utilising the latest 2D and 3D modelling design software to ensure we provide the best possible service with respect to functionality, longevity and budget.  We draw on many years of bespoke system design within multiple manufacturing industries to develop the most exacting solutions.

Our extensive experience allows us to offer design and operation consultancy services for a wide variety of materials handling & automation applications.

  • Concept Design
  • Research & Development
  • Engineering Consultancy
  • Project Management
  • System Design

Evaluation & Prototyping

For all engineering design projects we follow a simple process flow to ensure the end goal of achieving the correct solution is achieved.  This process involves a number of key steps commencing with definition of the problem, through the research and preliminary solution stages to the modelling and final solution creation.

For the majority of bespoke machine and system design projects we produce partial or full prototypes to prove the concept.  Such prototypes may be on a smaller scale or manufactured from temporary materials  to test the design functionality prior to committing to final design and manufacture.  This prototype development system not only reduces wastage but also optimises project development and manufacture times whilst ensuring any design errors and functionality problems are rectified quickly and efficiently.

Assembly & In-house Testing

Where possible all equipment is fully assembled in our workshop prior to packing and delivery for quality control purposes and to ensure functionality.

Following mechanical assembly the associated control panels are mounted and all machine electrics such as motors and sensors are fitted and wired.

The system is then tested, firstly without material to check basic functionality and to ensure the control software operates correctly.  Where possible materials are introduced to give a true representation of the machines site operation.

Installation & Commissioning

We supply our customers with varying levels of service depending on their specific requirements.  From equipment supply only to installation supervision and full mechanical and electrical installation services.

From single stand alone machines to complete site installations incorporating machinery, support structures and access platform and plant wide control systems we can provide site engineering services to suit your specific requirements.

Following installation we offer a comprehensive system commissioning and plant start up service to fully verify the installation whether it be by ourselves or via a customer appointed third party installer.

Our experienced commissioning engineers will conduct dry system trials to ensure all physical plant functions operate correctly before introducing materials to conduct live system commissioning.

On site operator and maintenance staff training is provided to ensure smooth plant operation and reduce potential future downtime due to poorly educated staff members.

Service & Support

Our dedication and support to our customers doesn’t end at installation and site commissioning.  We offer a range of after sales services and support packages ranging from pay as you go maintenance to annual calibration visits and full service contracts.

Service contracts are all tailor made to suit your specific installation and the equipment covered and can include multiple levels of cover:

Bronze

  • Telephone support

Silver

  • Telephone support
  • Service visits

Gold

  • Telephone support
  • Service visits
  • Remote software access

Platinum

  • Telephone support
  • Service visits
  • Remote access
  • Spares discount

Traditional Minor Ingredient Systems

Traditional minor ingredient systems were generally based around static central batch weighers with a number of material feed stations positioned around its perimeter.  Such systems would either weigh directly into a bag or first into the weigh vessel then discharge into the bag.  Such systems can suffer from lower accuracy, contamination, slow throughput and limited or no expansion possibilities.  C J Waterhouse company developed the Smart Cart system to overcome the negative constraints.

The 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 incorporates 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.

Automatic systems for bucket, container and bulk IBC can also be supplied although the latter would normally be located upon a linear track.

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

Bag Manufacture & Handling System

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.

Material Storage & Dosing

The system is designed to incorporate bulk material delivery in FIBC’s or sacks.  These delivery methods are catered for using either sack tip stations or bulk bag discharge stations.  In both cases the materials are discharged into surge / feed hoppers located beneath.  Numerous material storage facilities with integrated feeders are positioned around the track perimeter.  These feeders can be either vibratory or screw type dependent upon the specific material being handled and all are fitted with pneumatically operated catch gated to improve weighing accuracy and eliminate over-run or spillage.  In addition to the standard material feed stations manual addition stations and ‘bag-in-bag’ stations can be incorporated as required.

Control & Automation

The control philosophy is based around a central  control panel housing the master PLC and associated hardware for the off-track functionality of the system.  Each Smart Cart weigh carriage incorporates a small PLC unit providing independent speed control, anti-collision control, weight signal conditioning and positioning control.  Communications from the master PLC panel are sent using a wireless blue-tooth system while power to the carriage drive is received via an enclosed copper Bus system which runs around the perimeter of the track.

The central control panel incorporates a PC based recipe handling and production scheduling system which sends individual recipe requirements to each carriage as a new bag is loaded.  The carriage will then commence its cycle and feed weighment data back to the central panel for batch logging and data reporting.

A PC based SCADA system provides system and carriage monitoring together with a user friendly human machine interface.

Plant Control

CJ Waterhouse Co. Ltd provide customised plant wide control and automation solutions for both mechanical equipment supplied by us and for third party machinery and process lines.

Process line automation systems incorporate machine starting applications, automation hardware / software, communication networks and data presentation systems to provide a truly turn-key solution.

From initial consultation to system design right the way through to commissioning and plant start up we closely liaise with our clients to ensure the best possible automation solution is achieved for your specific plant requirements

CJ Waterhouse Co. Ltd provide customised plant wide control and automation solutions for both mechanical equipment supplied by us and for third party machinery and process lines.

Control Panel Design & Manufacture

Automation control panels are designed in-house by our electrical systems engineers to provide plant specific machine and process operation.

All our panels are designed and manufactured to the highest standards and utilise off the shelf components from some of the worlds largest and trusted automation component manufacturers such as: Siemens, Schneider, and Pilz to name just a few.

We adhere to all current design and wiring legislation and can supply control panels to satisfy worldwide requirements in terms of quality, safety and international legislations.

Software Development

All plant automation software whether it be for PLC sequence control, SCADA / HMI data presentation or PC based scheduling software is developed in house by our team of systems engineers.

Close liiason with our customers ensure we supply software solutions to provide fully automated software system to operate your plant the way you want.

We can develop PLC, SCADA & HMI software for any industry utilising the platform and manufacturer of your choice, such as:

  • Siemens
  • Mitsubishi
  • Allen Bradley
  • Omron
  • Schneider
  • InTouch

SCADA & HMI Systems

SCADA & HMI systems provide plant  operators with an effective interface to the associated machinery and processes. Such systems are utilised to provide the user with live information both in graphical and data format together with permitting system configuration and set up.

More complex systems can incorporate material stock control, in depth batch reporting and diagnostics along with live and historical trending.

Our SCADA and HMI systems are developed in-house and are designed to exactly reflect your plant equipment and specific site requirements.  Through initial and ongoing engineering discussions we get a true understanding of your manufacturing process and develop a data presentation system that reflects your exact process.

Clear graphical displays and data tables together with simple configuration screens and operator controls ensure that our software solution fulfil your most exacting requirements with respect to functionality, ease of use and budget.

KS-Series Production Control

Our KS-Series software provides automated production control and scheduling for both single and multiple batching & mixing process lines.  The software operates upon a Microsoft Windows platform and has been developed to have a similar  appearance and functionality to that of commonly used Windows software programs.

The bespoke software is based around a Sequel Server database system which permits real time access from multiple terminals.  The database houses all raw materials together with specific mixing or process functions from which  individual recipe’s or compounds can be created.

Once a recipe has been created and saved it can be added to the schedule list for production where numerous batch specific settings can be applied such as total quantity, scale factor etc.

Created recipes are all given individual reference numbers and can be copied, pasted and edited to create a new formula.

The system stores all completed batch data including target weight, actual weight and specific data as batch logs which can be printed, exported or simply saved for future reference.  These batch logs can be located by performing a date range, compound type or material inclusion search at any time.  Each KS-Series software package is custom developed for the customer to incorporate their specific production requirements, unnecessary options are removed from the interface to keep the system user friendly and as simple as possible.  Like wise additional functionality can be added for more complex production requirements.

FIBC & Bulk Packing

Our bulk bag filling solutions come in a variety of formats to suit your specific requirements.  From single position volumetric filling stations with manual push button control to fully automated multi-position lines incorporating automatic pallet dispensing, neck sealing and take off systems.  Such systems incorporate high accuracy multi-point loadcell weighing for precise filling.

FIBC filling stations can be supplied for single size bulk bags or to cover a range of bag heights and can incorporate either manual or automated height adjustment dependant upon your requirement.

Manual & Semi-Automatic Sack Filling

For lower throughputs and production requirements we can offer basic sack filling solutions with either manual or automated bag loading, removal and sealing. Systems can be supplied to work with any bag shape, size and material with batching accuracies and throughputs to suit your production requirements.

Such systems generally incorporate gravity roller conveyor systems for manual transfer of bagged materials from the filling system to the sealing station and can be supplied with either gross or nett weighers dependent upon the specific requirements.  Bag closure can be either by heat sealer for plastic materials or stitched for paper and woven materials.

Automated Packing Lines

C J Waterhouse are the UK partner to Umbra-Packaging, one of the world’s leading experts in automated open mouth bag packaging and palletisation systems.

From their headquarters in Perugia Italy, Umbra manufacture a range of high speed placing, filling and sealing machines for pre-made bags.  Their machinery is capable of handling any bag type with integrated handles, slide locks and bespoke fastening systems at sizes from 300g to 30Kg.  Single and duplex machines are available with packing speeds of up to 2000 bags per hour.

Umbra manufacture two basic lines of packaging machine; the UP1000 which handles larger format bags from 1 to 30Kg and the UP-Mini which handles smaller pack sizes from 300g to 5Kg.  Both machines are available with a number of options to suit the customer’s specific requirements.

Palletisation

Automated palletisation solutions can be supplied using one of two methods depending upon the required throughput.  The first is via a three axis robotic arm which collects the sacks from a roller conveyor and positions them upon the pallet one at a time.  Multiple pallet configurations and stacking heights can be achieved.

The second method if for high throughputs and collects the bags in a similar fashion to that of the roboitic arm system.  The main difference is in the layering method whereby the machine creates a full layer of bags upon an opening plate system under which the empty pallet is located.  When a full layer has been created the plates open and the layer is moved to the pallet.  This operation is repeated a number of times until the full pallet stack is created.  Between layers the pallet is pushed upwards onto the underside of the plate to flatten the layer.

Bespoke Machinery

In addition to our standard range of bulk materials handling, weighing and automation solutions we have extensive experience in the design, development and manufacture of bespoke machine solutions to overcome our customers very specific process requirements.

Whether your requirement is simply to handle very specific material types or to automate a particular process requiring a one-off bespoke machine we can offer the correct solution to meet your exact needs.

From special product manufacture to bespoke packing solutions, we provide highly innovative machine and system solutions with respect to operation, budget and longevity.  Our engineering team have vast experience within numerous manufacturing sectors from recycling to pet food ingredients and can provide you with a tailor-made solution to overcome your process and manufacture problems.

Batch Weighing – Powders & Pellets

Batch weighing systems generally comprise of a central hopper or vessel mounted upon a multi point loadcell weigh frame.  One or more feeders are positioned around the weigher perimeter and are used to automatically dose materials into the weighed vessel in accordance with the specified recipe.  The physical form of the weigher can vary dependant upon material and the specific process requirements  but would generally be either a conical or rectangular hopper.  Other applications may however require a conveyor type batch weigher or specific bespoke solution.

Our batch weighing solutions incorporate automatically operated discharge systems and can include a number of discharge aid methods including; airation pads, fluidised cones and flapper jackets to enhance the flow of difficult to handle materials.

Batch weighers can be supplied in a wide variety capacities from just a few grams to multiple tons with accuracies and weighing ranges to suit your production requirements.

Batch Weighing – Liquids & Solids

As with powders, liquid weighing systems are designed around a central weigh hopper with liquids being dispensed via pneumatically operated feed valves.  Liquid feeds may be supplied from bulk storage tanks, intermediate bulk containers or standard drums with delivery pumps to suit.

For multi-batch operation systems the weigh hopper can discharge into a intermediate holding vessel situated beneath.  From the holding tank the liquid is pumped on demand to the downstream process.

Complete discharge of the oils and line cleaning is achieved utilising low level probes and air operated purging systems.

Both weigh hopper and holding tank are housed in a free standing enclosure which may be fitted with electrical heating and insulation for the handling of more viscous oils.

Solid material batch weighing systems generally comprise of a belt conveyor mounted on a multi-point weigh frame and provide weighing and transfer of batches to the downstream process.  Loading can be performed either manually by the operator or via an automated conveyor system.

Continuous Weighing Systems

Continuous weighing systems are utilised for applications where the process is of a continuous nature rather than that of a batching process.  Such systems generally comprise of either a continuous weigh conveyor or a duplex hopper system.

Continuous weigh conveyors comprise of a belt conveyor where a section of belt is weigher via a roller assembly mounted upon a loadcell weigh frame.  This frame can incorporate a single or multiple rollers dependant upon the material and specific throughput requirements

Duplex hopper systems comprise of two batch weighers operating inversely to each other to provide a continuous output of weighed material.  As one is weighing the other is discharging and vice versa.

Loss In Weight Systems

Loss in weight weighing systems provide automated discharging of materials by weight to the downstream process.  General operation will involve the top up of the weigh vessel by mechanical or pneumatic transfer prior to discharging the required weight of material.  Refill of the hopper can be controlled by level probe or weight.  Loss in weight systems are normally utilised where accuracy requirement is lower and the batch size is similar for all weighments.

Bespoke Weighing Solutions

With years of experience providing weighing system solutions for our customers we can design, supply and implement a bespoke weighing machine to suit your specific plant and materials requirements.  From raw materials to finished product weighing and check weighing systems we endeavour to supply the best possible solution with respect to accuracy and longevity.

Circular Screens

Circular vibratory screens can be supplied for all product applications from food sectors to aggregate industries in both wet and dry applications.  In such systems the screening assembly is mounted upon reactive springs and can incorporate multiple decks giving up to 4 fraction separations.  Each deck is fitted with a dedicated outlet chute to provide separated material streams.  Machine components and deck assemblies are secured with quick release clamp systems to permit rapid cleaning and mesh changing.

Machines can be supplied in varying diameters to suit materials and throughputs and can incorporate ancillary components such as top covers, material chutes and mesh de-blinding systems.

For simple screening of oversize particles and foreign bodies compact safety screens can be utilised.  Such machines are supplied a single deck units with a central outlet below the mesh screen and incorporate twin outboard vibratory motors providing vertical / horizontal amplitude vibration.  Oversize particles remain upon the mesh until manually removed.

Rip & Tip Screening Systems

For the manual emptying of bags containing powder or granular products. The product contained in the bag is emptied into the hopper and subsequently sieved particles are captured within top deck. Particularly suitable for the food sectors for policing of ingredients. These systems can also be using inline as part of FIBC bag filling / discharge stations.

  • Quick Disassembly
  • Stainless Steel Contact Parts
  • Removable Internal Components
  • Mobile or Fixed Location
  • FDA Approved Seals
  • Compact Design

Linear Screens

Linear Flatbed Vibratory Screens are capable of handling a wide range of materials and particle sizes.  Their vibratory action and use of mesh or perforated plate decks allows fraction separation of product into various streams.  Multi deck units permit separation of up to 4 material fractions.

Such screens can be supplied in both open and fully enclosed trough formats with either reactive spring or rubberised suppression systems.  Drives can be via standard vibratory motor providing single speed operation or electro-magnetic drives to give variable speed control to suit the specific plant requirements.

Units are custom designed to suit the specific materials and physical plant layout and can be supplied in materials from mild steel to 316 grade stainless steel.

Bespoke Screening Solutions & System Integration

Both linear and circular sieves can be custom designed together with bespoke frameworks to allow incorporation within your specific plant process.

From direct bulk bag filling solutions to custom separation systems we can develop a system concept to fulfil your specific separation and sieving requirements.

Sieving units can be incorporated within your existing site equipment and can be utilised not only for separation purposes but also as feeding devices.

Complete process solutions can be provided to embed sieving capability into: conveying systems, filling & discharging systems, weighing applications etc.

Feeding & Dosing

Feeding and dosing systems are designed to accurately dispense your materials to a specific downstream process, storage vessel or weighing system.  For precision dosing systems we incorporate feeder shut off valves or catch gates and variable speed drives to ensure the highest level of accuracy is achieved.  All our systems are custom designed to suit our client’s requirements with respect to speed, throughput and accuracy.

We supply a variety of dosing & feeding equipment to suit your specific material requirements from fine powders to granules, liquids and solids.  From belt feeding devices to screw conveyors we can provide the correct solution to handle your materials efficiently and carefully.

Screw Feeders

Dosing screw feeders are generally supplied for applications where accurate dispensing of powders is required.  Such feeders are custom designed to suit the specific materials and throughput requirements.  Feeders can be supplied with tubular or ‘U’ trough casings with removable top plates.

The majority of feeders are supplied with rigid casings and solid shafts with welded flights, however flexi-screws can be supplied where the unit comprises of a curved or flexible tubular casing with a flexible coreless flight helix.  Such systems are useful where elevation is required but a straight feeder body is not achievable.

Single or twin helix agitators are incorporated for difficult materials to reduce bridging and promote a constant flow of material to the feeder flight.

For applications where higher batch sizes and varying throughputs are required specialist feeders can be supplied which include duplex flights of different diameters to increase throughput range whilst maintaining accuracy.  For maximum throughput both flights are run simultaneously and for maximum accuracy just the smaller flight is run.

Vibratory Feeders

Vibratory feeders are extremely versatile and capable of conveying and dosing a wide range of material types from powders to large granules and solids.  These feeders comprise of a trough assembly mounted to a support frame via anti-vibration mounts.  Single or twin vibratory motors are mounted to the trough to provide material movement via amplitude vibration.  Manual adjustment to the feed rate can be made by setting the offset of the motor weights.

For applications where variable speed control is required vibratory feeders with electromagnetic drives are utilised.  Such drive systems can provide instantaneous speed control from 0 – 100% without any speed lag and are typically ideal for weigher feed systems where variable speed control is required to achieve both speed and accuracy.

Both vibratory motor and electromagnetic feeders can be supplied as open tray type or with removable lids and can be manufactured from mild or stainless-steel dependent upon the client’s specific production and physical plant requirements.

Bespoke solutions can also be supplied incorporating multiple inlets and custom trough designs, outlet configurations and discharge gate assemblies.

Belt Feeders

Material dosing can also be provided via belt feeding devices.  Such feeders can provide accurate dispensing of both powder and granule materials and have low impact on the conveyed material due to the gentle nature of the conveying method.  Our belt feeders can be supplied with either constant rate or variable speed drives and can incorporate multiple inlets and discharge catch gates.

Dense Phase Pneumatic Conveying

Dense phase pneumatic conveying systems transfer product as a slug of material at slow speed under high pressure.  Dense phase systems normally operate as a batch transfer system where a batch of materials is weighed and discharged into a pressure vessel.  The vessel is then pressurised, and the discharge valve opened therefore forcing the material along the conveying pipeline.  This type of conveying system causes less damage to delicate materials which are susceptible to degradation when transferred at higher speeds.

Material is transferred to the receiving vessel which is fitted with a reverse jet filtration system which separated the transferring air from the material via a series of filter cartridges.  The cartridges are automatically cleaned between batches using reverse air jets.

Lean Phase Pneumatic Conveying

Lean phase pneumatic conveying systems transfer product as a stream of material suspended within a higher speed conveying gas under lower pressure.  This type of transfer system can be utilised for both batch and continuous production and uses a blower unit to force conveying air along a pipe line into which the material is introduced.  Material is generally fed from a discharge station or a weigher into the conveying line via a rotary valve which not only delivers material at a constant rate but also separates the upstream equipment from the conveying pressure.

Vacuum Conveying

Vacuum conveying systems operate in reverse to a lean phase, positive pressure system where material is transferred from source to destination via a vacuum pump or inverse blower.  Air is sucked out of the transfer pipe line which causes a vacuum and therefore pulls the material along.  This type of transfer system can also be utilised for both batch and continuous production systems.

Vacuum transfer systems generally utilise rotary valves or similar feeding system to control the flow of material into the line and normally incorporate a filter or cyclone unit on the receiving vessel to separate transferring air from material.

Venturi Conveying Systems

Venturi systems use the principles of fluid dynamics to create both  negative and positive conveying pressures.  A negative pressure is created upstream of the unit and a positive pressure is created downstream.  Such systems are therefore very effective in sucking material from its source and supplying it to the destination under pressure.  These systems convey materials using lean phase technology and utilise either a cyclone of filter unit at the destination to separate conveying air from conveyed product.

The venturi  system works by creating a constriction within the pipe (classically a hourglass shape) that varies the flow characteristics of the gas travelling through the tube.  As the velocity in the throat is increased a consequential loss in pressure occurs.  This drop in pressure therefore creates a vacuum effect which can be used to draw material into the conveying pipeline.  On the downstream side of the venturi unit the material is conveyed using the positive pressure air flow.

C J Waterhouse company are a UK distributor for Kongskilde, a leading supplier of venturi systems around the world.  Their extensive experience within material conveying using fluid dynamic principles has led them to provide a unique system which vastly reduces air consumption and reduced end of line filtration requirements due to their air return system.  This system removes a portion of the air that is supplied to the venturi to create the vacuum and returns it back to the blower unit to be recycled