PAKstation Increases Leading Apple Producer’s Line Speed By 15%

Introduction

Adrian Scripps is one of the UK’s premier growers and packers of English fruit. With five farms and a packhouse covering 750 hectares, efficiency and innovation are important to the company hence the significant investment in automation.

The Story of Adrian Scripps

Based in Kent, Adrian Scripps grow and pack a variety of produce including Braeburn, Jazz, Gala and Bramley apples, along with Conference pears and blackcurrants. A key Tesco supplier, their commitment to innovation, such as automation, has been key to building and maintaining its market-leading position.

The Challenge

Historically, apples were sold either loose in moulded fibre trays or in plastic bags with a neck tie. Both packing operations were entirely manual and packing staff worked at an average rate of 2.5-5 packs per minute. When Adrian Scripps took the decision to invest in flow wrapping equipment, this accelerated the speed of the packaging operation and left up to 3 people trying to manually pack flow wrap apples into retail crates at a rate of up to 60 per minute per line. The packing operatives were unable to keep up with this pace, which meant upstream efficiency improvements from the company’s grading and flow-wrap investments were impacted. It was clear that an alternative solution was needed.

The Solution

Brillopak’s engineers designed a semi-automated version of the traditional ‘Lazy Susan’ style packing station for Adrian Scripps. Branded the PAKStation, it optimises, rather than replaces, human labour and has become one of Brillopak’s best-selling packaging solutions. The solution sees 1 person feed empty crates into 2 PAKStation systems. A roller conveyor then transports them to the operator. Bags of apples coming directly from the flow wrapper are transported into the system on a second, higher level conveyor.

The operator simply picks the bags off the moving conveyor and places them in the crate. Filled crates exit the PAKStations and converge onto a single infeed into a robotic palletiser, also supplied by Brillopak. You can read about the full end-of-line system here.

The Result

Because there is no accumulation, packing has to be consistent thereby putting the PAKStation – not the operator – in control of line speed. It also minimises operator movement by feeding product at the right height and in the right orientation. As a result, the PAKStation has made a real difference to Adrian Scripps’ crate packing efficiency, typically increasing line speed by 15% across a shift.

The Bottom Line

“You can honestly trust Brillopak. A British company, on our doorstep, at the forefront of their field. They’re innovative, proactive and delivered everything we asked. We couldn’t have worked with a better partner on this project.”

James Simpson, Managing Director, Adrian Scripps

If Adrian Scripps’ challenges resonate with you, book a call with us for some expert advice.