Fully automated crate loading and packing system for multi format packing lines for packaged meat pr

Description

Scope of new machinery • Empty tray destacking system Destacking and conveyor system to enable stacked plastic trays of 600mm x 400mm and 300mm x 400mm at various heights by means of pneumatic or vacuum system and deliver to the required end of line location. A system shall be in place to ensure there are no double stacked trays. • Empty tray conveyor system. Motorised inverter driven conveyors must transport the plastic trays from the destacked location the crate loading location approximately 2m away. Construction of conveyors must be 304 stainless steel or higher grade, constructed in a way to enclose any open ends and resistant to bacterial growth. Belt is to be plastic construction (Intralox type) • Conveyor system for products The conveyor system must transport the closed product approximately 10.0m from the end of line labeller to the packing position in the correct orientation for the pick and place robotic packing system. This may require a 90deg conveyor. The belt construction must be food safe material of Intralox type. Conveyors must be constructed of 304 or higher grade stainless steel and constructed in such a away to be resistant to bacterial growth with all open ends to be enclosed. • A synchronised system must be employed to ensure the crates are in the correct position and orientation for the product to be loaded by the automatic loading device such as a “pick and place” robot. • Automatic loading of crates with product The automatic loading device such as a pick and place robot must be able to pick all types of products with a minimum capacity of 8kg (including weight of the lifting head). The packing machine must have the capability to automatically detect products and place into the crates in the correct numbers, with the capability of image capturing equipment and storage for future reference. The automatic product loader must be capable of multiple product sizes and orientations with quick changeovers and maintenance friendly wear parts. All programmes must be easily amendable via a password protected screen with online monitoring. Crates and also Cardboard boxed will need to be loaded by the system. • Final loaded tray motorised conveyor system Loaded tray motorised conveyor system must transport the full trays from the packing station to the final manual palletising system. At a distance of 9m with a dog leg configuration to offset for pillars. • System to incorporate IOT with video camera system to monitor and supervise of the system remotely to ensure best efficiency and best performance (OEE). Any incidence or alarm is to trigger the IOT about the anomaly , then video of the specific camera that monitors the area of the equipment is to be saved for review by client and or OEM for RCA to take place. Example below of camera system locations:- • Electrical and controls cabinet The controls cabinet shall have a single supply from existing site services. From this supply all conveyors, automatic loading device, and all controls for stop start. Estop and any auxiliary equipment that may be required for the system to work. The construction of the cabinet must be of stainless steel of solid construction compliant with food industry standards. Indication lights must show the status of the system – Healthy, In fault, and running as a minimum. All cables must be suitably contained and earthed as in accordance with UK safety directives and UK machinery safety legislation. Access to panel must be lockable and only accessible with the use of a specialist tool and interlocked to ensure the doors cannot be opened while power is supplied. • Assembly commissioning and Training Installation and integration of the machinery must be completed by authorised and suitably qualified engineers. Installation of programs is to be held on the companies cloud based server, all programs become property of Dunbia (a division of Dawn Meats) after commissioning final sign off are complete. Training is to b