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Paper Handling – PJP’s Perplexing Paper Project

Paper Handling – PJP’s Perplexing Paper Project

Oct 3, 2024

Case Studies

Paper Handling – PJP’s Perplexing Paper Project

Paper comes in all shapes and sizes

A customer approached us wanting a turnkey solution for handling paper.

Sounds easy?

Well…

Several issues made their request a challenge. One particular obstacle was the need to centralise round discs of paper, that could be of different diameters, onto a conveyor. In fact, the product could weigh up to 50 kgs and have a diameter ranging from 300-600mm.

 

Design skills at the ready for paper handling

PJP pondered the issue before using our specialist design capabilities to create a simple, cost-effective bespoke solution in both 2D and 3D drawing packages. We worked with the customer, using and valuing their input from the initial concept design stage through to detailed design… and the eventual manufacturing of the solution.

A new paper handling invention: the product centraliser

The resulting ‘product centraliser’ that we created was able to centralise a paper core product to within 1-2mm of the conveyor centre line. This meant that the customer’s overhead robot could pick and place its gripper to into the core of the product exactly on the centre line of the conveyor. It would then lift and transfer the product onto awaiting pallets.

The solution also included an overhead timing belt system to accurately move the centralising mechanism in conjunction with a low friction modular belt conveyor which reduced wear on the base of the product.

Not just a pretty face

This is a great example of listening to the customers complex requirements, using our experience and creating an ingenious new paper handling system. Another bespoke solution designed and manufactured by PJP Conveyors.

We are more than just a conveyor company!

 

Paper handling new invention

Now you’ve seen what we can do, why not see if we can help you

Please get in touch with any new handling ideas you are thinking about introducing into your business – no matter how difficult they sound.

Rapid Conveyor Solution to Help National Retailer Cope with Christmas

Rapid Conveyor Solution to Help National Retailer Cope with Christmas

Dec 7, 2023

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

PJP’s Solution to a Common Warehouse Challenge

PJP’s Solution to a Common Warehouse Challenge

Jan 6, 2023

Case Studies

PJP’s Solution to a Common Warehouse Challenge

A pet-food warehouse conveyor challenge

A pet-food supplier approached PJP to look at ways they could streamline their end of line / despatch process. Traditionally, this critical order despatch process can be a bottleneck for many operations.

The specific challenge was to design a transport conveyor which could deliver totes of picked product to sixteen dedicated packing benches. Operators then needed to be able to pack the products into delivery cartons, apply a courier label and send the completed order to a single despatch location. No walking with, or lifting of, any product during the process was allowed.

Bespoke conveyor design on two-levels

PJP designed a bespoke two-tier warehouse conveyor system with the following capabilities to achieve this:

  • The top tier delivers totes to packing bench positions using Zero-Line Pressure (ZLP) technology. This ensures no collisions or finger traps during use – health & safety is very important to us and our clients.
  • Specially designed packing benches (workstations) then allow operators to simply slide the tote onto their workstation and process it.
  • Once complete, operators use the lower tier by sliding the completed, boxed order onto a small decline belt. An intelligent traffic light system then  automatically drives every box in the warehouse to a dedicated despatch point with no human action required.

Space saving solution

We also very much needed to keep the footprint of the system as small as possible. Space in any warehouse operation is a very valuable commodity. The two-tier setup and twin lane approach gave maximum performance whilst keeping the footprint to a minimum.

Serious uplifts in productivity

Prior to this warehouse conveyor system being implemented, the client was achieving a completed order every 3-4 minutes. The new system allows them to achieve a throughput of one order every 10 seconds. All in all, a very attractive return on investment was achieved which eliminated manual lifting and walking from the process.

Challenge accepted and solution delivered!

Warehouse conveyor that streamlines end of line
Small decline belt on warehouse conveyor
Warehouse conveyor packing benches

Let us help you too

Why not get in touch to tell us about your warehouse challenges? With our skills in designing affordable conveyor solutions that solve your problems, we are sure we can assist.