Switching to automation has streamlined Gripple’s packaging operation, vastly speeding up the process, and enabling it to continue its fast-pace expansion. Gripple is an award winning manufacturer, producing a patented wire joining and tensioning device in Sheffield. Its original product was launched in 1988 and there are now over 500 variants sold across 75 countries. The company’s rapid growth – now turning over in excess of £30m per annum – is based on their core value of innovation, says Darren Cork, manufacturing systems manager at Gripple.
“We purchased two Autobag AB 180 bagging machines in 2006 because our previous packaging system was unable to cope with our increasing productivity,” says Darren. “Our old machinery did a great job but wasn’t automated, so it was too slow and demanded a lot of labour.
“Recognising the need to reconsider our packaging operations, we invited Automated Packaging Systems to come and assess our needs and discuss our options. Following some rigorous testing we chose the two AB 180s,” he says.
Gripple’s packaging requirements are unusual – its core operation involves packaging two different items into one bag. Automated Packaging
Systems and Gripple collaborated to develop a customised twin bowl system, allowing the process to be fully automated.
“The dual bowl system that we developed saves the need for somebody to manually drop items into bags. It’s a significant improvement on the single bowl feeder that we used before, and this alone saves us 50 hours of labour every week,” reflects Darren.
“With the current system we pack around 150,000 units a week, this wouldn’t have been possible with our old system. Previously we’d pack 1,000 units a day, but the AB 180 can do this in two hours.
“The AB 180 is even faster than the machines which manufacture the products – the bagger can easily pull ahead of manufacturing. We don’t need to run it on the night shift because the AB 180 can so easily catch up.”
Flexibility is an important asset of the AB 180 at Gripple. Customers fall into two distinct groups, agriculture and industry, and it produces several different products for each. “Using the AB 180 we do 15 different packing variations,” adds Darren. “As well as packing several different products, we also pack in various volumes. It is important that we can tailor it to the individual customer’s requirements.
“Consistency and reliability are also important to us. We work out continuity and consistency, and when we installed the machines we demanded less than a 2% rejection rate. It is now down to 1.8%, far better than the 4% that we achieved with the old machines. And the machines very rarely breakdown. On the rare occasion that they do, Automated Packaging Systems fix them, quickly and easily. One of our machines ran for 5 months without stopping – it never failed.”
“Training is needed to get to grips with the machine, but as long it’s provided they are straightforward,” insists Darren. “The control interface is good and the touch-screen display is a significant improvement.
“Even changeover between runs is easy. It takes a few minutes to set up the bowl but otherwise it is a simple case of feeding the new bags through and changing the pre-set menu. Once it is done you can leave the machine alone. You can tell by the sound when you need to get back to it, but it is so fast you need to stay close.
Importantly the quality of the end product is also good and the inbuilt PI 412c printer keeps the packaging operation straightforward and fast. The AB 180 enables Gripple to bag, label and pack in one seamless process. Without it, Gripple simply wouldn’t be able to keep up with current levels of demand.
For more information about Automated Packaging Systems and its products visit www.autobag.co.uk, telephone 01684 891400
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