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

High-Speed Product Sorter Conveyor System for Footwear Supplier

High-Speed Product Sorter Conveyor System for Footwear Supplier

Case Studies

High-Speed Product Sorter Conveyor System for Footwear Supplier

A colossal conveyor challenge

PJP were tasked with the design, build, installation and commissioning of a high-speed sortation solution. This ended up being part of one of the largest conveyor systems we’ve ever supplied!

The remit was to sort shoe boxes into 102 destinations. This needed to support a pick process spread over a three-level warehouse that used thirty pickers. The pick process and transport conveyors (also supplied and installed by PJP) can output a shoe box at a rate of one per second. This meant the sortation solution needed to keep up with this extremely quick rate. No pressure then… 

Identifying the best components for the conveyor system

PJP compared many bi-directional product transfer units. Following various tests and consultations, we selected the Itoh Denki ‘F-Rat’ 24v transfer unit. It’s low noise, efficient transfer, high speed 24v technology and low maintenance were winning factors. The units also allow product separation and give a zero-line pressure feature for complete stability and accuracy. This is essential when handling a huge range of box sizes from 150mm x 150mm up to 600mm x 600mm at high speeds.

The conveyor system solution

We installed barcode readers into areas that could identify the individual boxes in the conveyor system. They did this by looking up the product and matching it to the relevant order. This scan result then instructed the system on where to send each shoebox to. 

We decided to create two sorters. The first sorter having sixty-six destination lanes and the other thirty-six.  

These sorters have enabled our client to automatically sort up to 3,600 individual shoe boxes per hour. This gets them safely to 102 locations. There is zero manual intervention or product handling from staff.

This is a staggering cost and labour saving vs manual sortation methods and is a prime example of what a conveyor system can achieve. 

 

Need to sort products in a better or faster way?

PJP can offer a huge range of product sortation options as part of our conveyor system solutions, please contact us for more information. 

Product sortation conveyor system for shoe boxes
F-RAT Transfer units on large conveyor system
Footwear off to its destination on conveyor system