Due to growing customer demand, pie producer Pukka is expanding retail production by introducing a new high speed, flexible packaging line into their manufacturing facility in Leicestershire. Bradman Lake was tasked with meeting the challenging of feeding a new high speed packaging leg from two existing process lines, with the ability to pack faster.
Working alongside Pukka, Bradman Lake developed a new layout providing new bridging transport conveyors and newly developed packaging machines with a small footprint. With high speeds and limited factory space, the company utilised its SL Minor, a high-speed end load cartoner with integrated servo driven star wheel feeder. The cartoner is coupled with a newly developed dual lane robotic six station wrap around case packer capable of up to 40 cases per minute.
The WR6 case packer is a fully automatic machine containing ‘back-to-back’ robots used to pick and place each carton collation into the case.
Each side of the case packer is equipped with low level hoppers and independently controlled case management and sealing, giving the customer the flexibility to produce different count SKUs on each side of the machine during the same production run.
Pukka’s planned shutdowns provided a window of opportunity for line modifications and the installation and commissioning of the equipment.
“We are delighted with the installation of the new retail packing line, further strengthening our ability to service retail demand, and cementing our ability to meet our ambitious growth strategy,” said Peter Gull, Engineering and Projects Manager at Pukka Pies. “Having challenged Bradman Lake to find a solution to a complex set of constraints, they worked closely with our projects team to provide a tailored solution that met our requirements. Our relationship with Bradman Lake spans many years, over which they have provided Pukka with end of line packing solutions to support our growth plans and range diversification, ensuring there is a Pukka for anyone, anytime.”
Visitors to the company’s stand at interpack will see in action its new IMF Intelligent Motion Feeder, designed to improve efficiency and flexibility, while increasing profitability. The IMF will automatically feed products into the FT120 Flow Wrapper. The wrapped products will then enter the DRT Dual Racetrack Robotic Toploader, which will pick and place products into cartons formed and glued on the HSS High Speed Servo Driven Carton Former. Filled cartons will transfer to the IL120 Carton Closer and are sealed using hot melt adhesive, demonstrating a flexible and modular top load cartoning approach.
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