Leading Cosmetics Manufacturer Benefits from PJP Pre-Planned Maintenance

Leading Cosmetics Manufacturer Benefits from PJP Pre-Planned Maintenance

Case Studies

Leading Cosmetics Manufacturer Benefits from PJP Pre-Planned Maintenance

One savvy cosmetics manufacturer has turned to PJP to proactively address potential issues in their conveyor operations before they escalate into more significant problems. As a manufacturing business, they need to be able to trust their machines and technology to run operations smoothly. An unexpected breakdown or equipment failure could spell disaster in terms of costly downtime, reduced productivity, eroded profits and unhappy customers. That’s why conveyor maintenance and support is key.

Conveyor maintenance checklists are crucial

PJP takes a planned and systematic approach to maintaining the customer’s machinery, equipment and systems. This involves regularly servicing and inspecting the customer’s operational assets. At our most recent visit, we meticulously went through a huge checklist of items.

We checked everything to do with their conveyor’s rollers, bands, shafts, chains, joints, gates, fan vents, sensors, pull cords, motors… then cleaned, fixed, re-positioned and re-tensioned as needed.

 

Safety is paramount in the operation

Our visits are also the perfect opportunity to assess the safety of the entire operation. This is a hugely important aspect of our conveyor maintenance regimes. Safety checks and inspections help identify potential hazards or faulty components that could pose a threat to employees’ well-being. By addressing these issues promptly, the customer creates a safer working environment, reducing the chances of accidents or injuries.

Reduce, reuse & recycle

When installing spares, in line with the customer’s wishes, we use reconditioned parts when possible. This had sustainability benefits and keeps down the cost of the service.

We now have a watch list for the parts of their conveyors that are likely to need attention when we next come over. Everything is done in collaboration with the customer so there are no sharp intakes of breath. Just a reliable and fully working conveyor system that will have a significantly longer lifespan due to the care that we are taking over it.

 

Looking after other manufacturers’ conveyors too

Did you know that we look after many conveyors that have been supplied by other manufacturers – not just the ones that we make?

To find out about our affordable servicing and maintenance packages for manufacturing, warehousing and distribution conveyors, get in touch for a no obligation quote.

Conveyor maintenance | Inspecting, cleaning & fixing elements
Conveyor Maintenence | Looking at systems from every angle
Conveyor Maintenance | Roller conveyor
Conveyor Maintenance | Electrical control conveyor system
Multi-faceted conveyor with rollers, belt & transfer unit

Conveyor Move and Upgrade for International Security Product Supplier

Conveyor Move and Upgrade for International Security Product Supplier

Case Studies

Conveyor Move and Upgrade for International Security Product Supplier

Industrial conveyors, like this one, sometimes need a bit of a facelift to support new processes. Working with what you already have and replacing sections can be a super efficient way to create a solution.

The requirement

PJP were asked to change the layout of a conveyor system by a longstanding customer in the security product sector. The customer also wanted to upgrade various sections. The aim for both of these requests was to fully support new processes.

A strategy that meant no downtime

PJP carried out the work over two weekends. This meant no downtime or hassle for the customer during their working hours.

Following 50% completion over the first weekend we left the conveyor in a working state in its new position. We had included a temporary outfeed to ensure the customer could continue as normal with picking, scanning and despatch. The project was complete by the end of the following weekend.

What we delivered

We removed the old and problematic transfers and replaced them with modern F-RAT units by Itoh Denki. These transfer units can reliably transfers items at horizontal 90 degree angles. 24v zero line pressure (ZLP) conveyors replaced an outdated belt driven roller section. Scanner outputs were changed to sortation lanes which suited new carrier label processes.

A newer version of programmable logic controller (PLC) software came next. We future-proofed the software to support operations both now and in the forthcoming years. We also adapted the human-machine interface (HMI) to the new layout and added in useful new HMI functionality.

Finally, we tested and commissioned the whole system with the client. This ensured it performed exactly as required.

Job done.

F-Rat Transfer Unit on Industrial Conveyor
Sortation Lane on Roller Conveyor Section
Curved Roller Conveyor Section
Camera Scanners on Industrial Conveyor System

Do your industrial conveyors need improving?

This is just one example of how we work with clients to enhance their conveyor processes to modernise them. PJP Conveyors pride themselves on listening to customers to fully understand their requirements before coming up with solutions that suit their needs and budget.

Contact us for expert guidance on improving your conveyors.

Rapid Conveyor Solution to Help National Retailer Cope with Christmas

Rapid Conveyor Solution to Help National Retailer Cope with Christmas

Case Studies

Rapid Conveyor Solution to Help National Retailer Cope with Christmas

A Christmas disaster strikes

This one didn’t involve an uncooked turkey, missing presents or the norovirus… but a retail conveyor. It wasn’t looking like it was going to be a great Christmas for this national retailer.

Their existing conveyor was finally beyond economical repair. It had been used 7 days a week for 12 years and its age and condition were showing. The conveyor was heavily relied on. It was the only method of staff getting bulky items safely between floors in the warehouse – including lots of potential Christmas presents.

Then, just as their sales were ramping up, their conveyor broke down.

 

PJP to the rescue

The organisation rightly called on PJP Conveyors to assist. We understood how vital these conveyors were to operations, especially so close to a major trading period.

Our strategy was to ensure continuous operations however we could. So we attempted a temporary repair to see them through the period until a new conveyor could be supplied.

Much to the delight of the client, we carried out the repair successfully. We, therefore, managed to eke out every last bit of use from the existing conveyor for a limited period.

This retail conveyor had seen better days
Old incline belt conveyor section
Old control section

A sustainable long term solution developed

Meanwhile, the rest of the PJP team pulled out all the stops. We got a new retail conveyor designed, manufactured, delivered & installed in less than 6 weeks from original breakdown being reported!

We also got all the associated electrical controls replaced and upgraded so that they met current safety standards.

Christmas miracles (available any time of the year)

This is the closest PJP and the client got to a Christmas miracle, because our quick thinking and speedy turnaround truly saved the client from a very sticky situation.

PJP offers a huge range of conveyor solutions, please contact us for more information. 

Shiny new belt section of retail conveyor
New conveyor section
New controls

Automated Solution for Cosmetics Supplier

Automated Solution for Cosmetics Supplier

Case Studies

Automated Solution for Cosmetics Supplier

The requirement

A leading cosmetics supplier required a warehouse automation solution. It particularly needed to weigh and measure each of their parcels and incorporate the resulting information onto a printed carrier label. The resulting solution would be an automated despatch process.

To achieve this, PJP would need to create what is usually referred to as a DWS (Dimensioning Weighing and Scanning) System.

 

The design

With the brief established, PJP designed and constructed an automated system to do the following:

  1. Drive boxed orders to a weigh scale conveyor and scan a 2D barcode.
  2. Match the label data from the client database to the correct order.
  3. Our DWS unit should then automatically take the weight and all dimensions of the parcel. It should output this data to our Programmable Logic Controller (PLC).
  4. Once the parcel arrives at the print and apply machine, it scans the barcode and produces a label containing the shipping address, dimensions & weight.
  5. Automatically apply the label to the parcel.
  6. Dispatch the order to the relevant carrier for delivery.

The system includes a reject lane to eject any parcels not expected at the DWS which allows the despatch line to run continuously.  

Just one of many warehouse automation options

Our DWS solutions can handle a huge range of product sizes from the very small to the massive. DWS is a proud offering within our warehouse automation portfolio which facilitates fully automated, reliable processes that are tailored to your requirements.

Our DWS options can interface with your in-house systems whether they are Enterprise Resource Planning (ERP) or third-party Warehouse Management Systems (WMS).

You can read more about DWS (also known as volumetric data units) in this blog we dedicated to them.

 

Want to talk to a human?

Contact us to discuss your warehouse automation requirements, whatever they may be. We look forward to having an open and honest discussion with you!

Warehouse automation | Automated despatch process
Warehouse automation | Label print and apply machine
Warehouse Automation | A box is routed to its particular destination