23 October 2013 | Astec Conveyors Ltd
Astec provide the missing link at Honeytop Speciality Foods Ltd
Founded in 1984, Honeytop Speciality Foods Ltd, Europe’s leading volume manufacturer of high quality, authentic naan breads and various types of flatbreads, recently invited Astec Conveyors to present efficient and cost effective proposals for the integration of new packaging equipment into their production halls.
At its modern production centre in Dunstable, where product is made in a controlled environment, two new RG Luma Automation lines were installed side-by-side to improve productivity, maintain hygiene standards and increase speed of production utilising FlexPicker robots for the picking and stacking of crumpets. The stacked crumpets are fed to four independent flow wrapping machines.
Honeytop Speciality Foods wanted Astec Conveyors to design a conveying system from the discharge of the flow wrappers in the production hall, through to the warehouse for packing into baskets or cases ready for hand palletising.
In principle this appeared to be simple, but in practice was less so, as the flow wrappers were located between the RG Luma lines and the space restrictions created difficulties for access and integration. Also, a clear passageway had to be maintained to allow pallet trucks free movement between the lines.
Astec Conveyors designed, manufactured and installed a stainless steel, food quality modular plastic belt conveying system, combining a series of 11.5cm (4 1/2”) slat conveyors plus 90° and 180° bends. Initial thoughts of incorporating a new spiral elevator to transport product from the flow wrappers to overhead conveyors had to be abandoned due to the space restrictions and the need to maintain clear access.
This challenge was overcome in co-operation with RG Luma, as the outer guarding of the Robot machines had to be modified to create a passageway through the machines. This allowed wrapped product to be discharged from the flow wrappers down a chute to a low level conveyor, to be transported through the machines, up an inclined modular belt conveyor and onto the warehouse via overhead modular plastic slat conveyors. This system optimised on the available space and maintained clear access for pallet trucks.
On entering the warehouse, product was conveyed to low level where it was transferred into a checkweigher, prior to being packed into plastic baskets or cases for hand palletising.
Astec Conveyors in-house control department designed a bespoke control system which would allow the conveyors to change speed depending on the production conditions. As one FlexPicker can handle the total production if required, the conveyor system automatically adjusts speed to suit.
Zizou Benchaoui of Honeytop Speciality Foods reported, “We have in the past developed our own bespoke production lines in-house, engineered with built-in flexibility to produce a wide range of sizes, shapes and weights of bread that can be topped or filled with a variety of ingredients.
Astec Conveyors were very professional and demonstrated a clear understanding of our needs, quickly responding to our enquiry and providing an efficient, cost effective solution. The whole project was superbly engineered, including all electrical / control equipment and was completed on time and within budget. Since installation the new handling system has performed successfully and Honeytop Speciality Foods have experienced the benefits of integrated and automated handling systems.”
Honeytop Speciality Foods wanted Astec Conveyors to design a conveying system from the discharge of the flow wrappers in the production hall, through to the warehouse for packing into baskets or cases ready for hand palletising.
In principle this appeared to be simple, but in practice was less so, as the flow wrappers were located between the RG Luma lines and the space restrictions created difficulties for access and integration. Also, a clear passageway had to be maintained to allow pallet trucks free movement between the lines.
Astec Conveyors designed, manufactured and installed a stainless steel, food quality modular plastic belt conveying system, combining a series of 11.5cm (4 1/2”) slat conveyors plus 90° and 180° bends. Initial thoughts of incorporating a new spiral elevator to transport product from the flow wrappers to overhead conveyors had to be abandoned due to the space restrictions and the need to maintain clear access.
This challenge was overcome in co-operation with RG Luma, as the outer guarding of the Robot machines had to be modified to create a passageway through the machines. This allowed wrapped product to be discharged from the flow wrappers down a chute to a low level conveyor, to be transported through the machines, up an inclined modular belt conveyor and onto the warehouse via overhead modular plastic slat conveyors. This system optimised on the available space and maintained clear access for pallet trucks.
On entering the warehouse, product was conveyed to low level where it was transferred into a checkweigher, prior to being packed into plastic baskets or cases for hand palletising.
Astec Conveyors in-house control department designed a bespoke control system which would allow the conveyors to change speed depending on the production conditions. As one FlexPicker can handle the total production if required, the conveyor system automatically adjusts speed to suit.
Zizou Benchaoui of Honeytop Speciality Foods reported, “We have in the past developed our own bespoke production lines in-house, engineered with built-in flexibility to produce a wide range of sizes, shapes and weights of bread that can be topped or filled with a variety of ingredients.
Astec Conveyors were very professional and demonstrated a clear understanding of our needs, quickly responding to our enquiry and providing an efficient, cost effective solution. The whole project was superbly engineered, including all electrical / control equipment and was completed on time and within budget. Since installation the new handling system has performed successfully and Honeytop Speciality Foods have experienced the benefits of integrated and automated handling systems.”