SubscribeThe first two LJ300M pick & place robot top loaders unveiled by Bradman Lake at PPMA 2003 will shortly be in operation at what its owner and MD Tim Wilson describes as "Europe's most efficient ice cream factory."
Each is linked with a Bradman Lake 2/60 erector and Compact R 3-flap FCC closer to create two fully automatic, fully integrated cartoning lines. One is dedicated to choc-ices, the other to fruit and milk lollies on a stick.
The 7400m2 Loseley Dairy Ice Cream plant now nearing completion on the Llantarnan Parkway near Cwmbran will be able to produce four times the present output of the company’s three leading brands, Loseley, Thayers and Yorkshire Dales. It will have total capacity of 10,000 litres/hr. from seven production lines, two on cartons and five packing tubs.
The Cwmbran plant demonstrates, in every department, state-of-the-art in ice cream production.
Computer controls all key processes: mixing, mix holding, pasteurising, homogenising, extruding and packaging finished products. All information is digitally recorded in real time, providing instant access to past and present production data.
Loseley’s MD Tim Wilson (rt) and Bradman Lake’s David Waters are happy with the first of two LJ300M robot toploaders soon to go into the new 7400M2 Loseley Dairy Ice Cream factory in Cwmbran.
Linking Bradman Lake’s LJ Toploader and ABB Flexpicker robot units with it’s erectors and closers creates fully integrated automatic carton packaging systems from a single supplier.
“I had no problem with being the first in UK to install the new LJ300M robots,” says Tim Wilson. “We already use Bradman Lake machines and know their expertise in high speed product handling here and in USA. I have confidence in their engineering quality, long life reliability and commitment to ongoing after-sales service. And they share my belief in being first in the market with new ideas.”
The LJ300M employs the same electronic motion controls, “smart belt” technology and ABB Flex-Pickers used in the 800ppm LJ Series of which there are over 30 in the States. Machine control and access to menus providing flexible, fast changeover is by touch screen operator interface.
At Loseley, random in feeds of flowrapped products will stream into the two LJ300M systems to be transferred into buckets on a vertical racetrack conveyor. Cartons formed by the 2/60 erectors will be accurately positioned by two sets of servo-driven side belts and the Flex-Picker robots will lift the collated products – 10 Luxury Choc Ices and 3 Chocolate or Fruit Maximums at a time - and load them into the open cartons.
Filled cartons then pass to Compact R Closers, which seal first the front and then the side flaps using Flexible Carton Control, and positive 90° turn to control the flow.
“Robotic product handling gives fast cycle times and great accuracy with reliability,” says Tim Wilson. “Integrating that with carton erection and closing equipment from a single supplier on our doorstep offers real benefits.”
Production efficiency at Loseley is matched by environmental responsibility. No waste is put down the drain; rather it is fed into three large reed beds for natural treatment. Cooling water for the compressors is obtained from two large lakes on site, which can be topped up by a state-of-the-art rainwater harvesting system.
Loseley ice creams are made with butter, sugar, fresh double cream and milk. Loseley is official supplier to all English Heritage sites, Wimbledon tennis and London theatres.The three brands are sold in multiple and independent retailers and served by caterers throughout the country.