The future of conveying

Simon Duddy: LB Foster has introduced ABB robot based automation. What advantages does this bring?

Gary Bale: There’s no doubt that robotics is the technology of the future. We are seeing the introduction of robots to replace manual labour in many of the industries we are involved with from the drinks business of Diageo to automotive manufacturing at the country’s leading car makers.

At LB Foster Materials Handling we are at the forefront of technology when it comes to integrating robotics into materials handling operations. The company has introduced high performance ABB robots into its advanced automated solutions. ABB Robotics is the UK market leading supplier of industrial robots and robotic manufacturing systems.

The commercial benefits of robotics are exceptional. Health and safety issues are lessened as robots can work in dangerous environments where it would be impossible for humans. At the Diageo cooperage in Cambuslang, two 7-axis ABB robots are used to manipulate casks during the charring process where the inside of the casks are exposed to flames. This is part of an innovative conveying solution with integrated robotics designed and installed by LB Foster for Diageo.

Robotic welding is increasingly used in car making, this increases the safety of the process as well as the efficiency – robots can operate non-stop 24 hours a day. The use of robots has also significantly reduced the incidence of repetitive strain injuries.

A further advantage is seen on the bottom line. Although the initial outlay for this type of technology may be expensive (however costs are going down due to mass production), in normal terms the ROI is 12 months or less which is a huge cost saving going forward.

SD: LB Foster has considerable experience in garment handling. How do you keep driving efficiencies here?

GB: Our task is to use automation to improve the mass movement of garments through a distribution centre. It is becoming apparent that our customers have a preference for flat packed garments in their warehouses – stored either in totes or cartons rather than hanging products.

This is for a number of reasons including cost, speed and ease of handling. We’ve recently completed a system of interfloor belt conveyors in Clipper’s Burton DC for SuperGroup’s brand Superdry. This is a 350,000 sq ft facility supplemented by a further 200,000 sq ft of mezzanine on three floors and almost all of the products inside are flat packed. 

SD: Can you tell us about changing trends in conveyor usage?

GB: Today’s stringent requirements for health and safety in the workplace are driving the changes in conveyor usage and this is true in factories, distribution centres, retail sites and automotive plants.

Much of the product which historically was moved manually is now moved on conveyors. Automation not only reduces the risk of injury to personnel it also increases both efficiency and productivity.

SD: Are certain types of conveyor or approaches coming into or going out of fashion?

GB: In the heavy industry markets we are increasingly being asked to quote for in-floor conveyor lines. Mounted within an excavated pit, this type of conveyor saves valuable space on the factory floor.

Manufacturers of earth moving vehicles are doing away with manual transportation of heavy product using overhead cranes and forklift trucks; instead they are turning to automated solutions. At Caterpillar Stockton, we designed, installed and commissioned conveyors and transfer cars at three important stages of the production process.

Environmental issues continue to play a large part in conveyor design. Saving energy is becoming increasingly important and there are various technologies we can utilise to help companies reduce their energy output. Conveyor systems which include a ‘die-back’ facility, only running when they are being used, are now the conventional choice. 

Dunnage conveyors are part and parcel of the modern distribution centre’s operation. LB Foster recently installed an innovative dunnage belt and chute system for Clipper’s Burton DC which handles the full range of multichannel distribution solutions for SuperGroup’s Superdry. The dunnage system is used to remove all of the waste cardboard from the facility’s three mezzanine floors and transport it outside the building to a compactor.

SD: What do you see as LB Foster’s key market strength?

GB: At our Leicester head office and manufacturing base we have a very knowledgeable group of people who are dedicated to the materials handling industry. Our key strength is that we use our in-house expertise to provide bespoke solutions to our customers’ automation problems in a wide range of industries.