Maximising Efficiency and Quality: The Benefits of Special Purpose Automated Machinery in Feeding and Handling

April 2024

In the ever-evolving landscape of industrial processes, efficiency and quality are paramount. Nowhere is this more evident than in the realm of feeding and handling within manufacturing sectors. Traditionally, these tasks have relied on manual labour, which can be time-consuming, labour-intensive, and prone to human error. However, the advent of special purpose automated machinery has revolutionised these processes, offering a plethora of benefits that enhance productivity, precision and safety.

1. Enhanced Efficiency

One of the most significant advantages of special-purpose automated machinery is its ability to significantly enhance efficiency. Automated systems can perform tasks at a much faster pace than manual labour, thereby reducing cycle times and increasing throughput. Whether it’s feeding raw materials onto a production line or handling finished products for packaging and distribution, automated machinery ensures a seamless flow of materials, minimising downtime and maximising productivity. To add to this, automated machines, if designed and planned correctly, can have the ability to produce data on most aspects of manufacturing, from inspection and OEE (Overall Equipment Effectiveness) to input/out data. This data collection is almost unlimited. This provides an incredible advantage over traditional manual operations.

2. Improved Precision and Accuracy

Automation eliminates the variability associated with manual handling, leading to improved precision and accuracy. Special-purpose automated machinery is programmed to execute tasks with consistent speed and accuracy, ensuring uniformity in product quality. Whether it’s dispensing precise quantities of ingredients in food processing or assembling intricate components in manufacturing, automated systems can achieve tolerances that are unattainable through manual means, ultimately leading to higher-quality end products. The abundance of innovative and advanced technologies ensures that the selection of appropriate equipment is not far out of reach and allows automated machine builders like SP Automation & Robotics to utilise their vast portfolio of technology partners to select the appropriate equipment for the given task. With Accuracy and repeatability, it is a given that improved quality will be the result.

3. Safety and Ergonomics

Automated machinery mitigates the risk of workplace injuries associated with manual handling tasks. By removing the need for repetitive and physically demanding tasks, automation promotes a safer work environment and reduces the likelihood of accidents. Additionally, special-purpose automated machinery can be designed with ergonomic considerations in mind, optimising the layout and design of workstations to minimise strain and fatigue on workers. Whilst safety is there to protect operators, good machine design also incorporates safety to protect the machine itself utilising fail-safe design and integration into the design to verify sequencing and functionality.

4. Flexibility and Adaptability

Modern automated systems offer a high degree of flexibility and adaptability to meet evolving production requirements. Programmable controllers (PLCs) and advanced sensors, Industrial PCs (IPCs), configurable servo drives, and vision systems enable automated machinery to adjust parameters on the fly, accommodating changes in product specifications or production volumes with ease. This agility ensures that manufacturers can respond swiftly to market demands and maintain a competitive edge in dynamic industries. With a high demand for customisation in products, whether it be for vitamin supplements, medical injection devices, or even food packaging, manufacturers are required to have equipment that will be a lot more than a dedicated one product system. The incorporation of equipment, such as Beckhoff’s XTS and XPlanar platforms, allows systems to be designed to allow products to be processed in different ways on the same machine to cater for the customising of products.

5. Cost Savings and Payback

While the initial investment in special-purpose automated machinery may be substantial, the long-term cost savings are undeniable. Automated systems operate efficiently around the clock, minimising labour costs and optimizing resource utilisation. Additionally, automation reduces waste and rework by minimising errors and inconsistencies, resulting in lower production costs and improved profitability over time.

Payback is always a hurdle on investment, and it is natural to want new investments to start to “pay their way” as early as possible. Industry is now opening its eyes to look at longer-term gains and accept the need for longer payback solutions. Although the slower gains, a correctly specified and designed machine can have the ability to produce products for decades. When payback is a major concern, there are also options to scale back the automation functionality and design simpler solutions that will also provide flexibility. Collaborative Robots (Cobots), for example, in many applications, can have a payback within a few months. The added advantage of these is the simplistic programming, low cost and, in some circumstances (after being risk assessed), the ability to work next to humans to relieve them of mundane tasks. Such systems can also be designed to be portable and easily retooled to multipurpose them for other applications to ensure a high level of utilisation.

6. Data Collection and Analysis

Special-purpose automated machinery generates valuable data throughout the production process, which can be leveraged for continuous improvement initiatives. By monitoring key performance indicators such as cycle times, throughput, and quality metrics, manufacturers can identify areas for optimisation and implement targeted interventions to enhance operational efficiency and product quality.

In conclusion, the adoption of special-purpose automated machinery in feeding and handling processes offers a multitude of benefits that drive efficiency, quality, and safety in industrial operations. By harnessing the power of automation, manufacturers can streamline their workflows, improve product consistency, and remain competitive in an increasingly demanding marketplace. Embracing automation is not just a technological advancement but a strategic imperative for businesses looking to thrive in the modern era of manufacturing.

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