Webster Griffin Helps Krysteline Technologies Increase Their Packaging Capacity

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Why Did Krysteline Technologies Contact Webster Griffin?

Krysteline Technologies is a UK based waste processor that collects and processes all shapes and sizes of glass. They use patented technology to repurpose 100% of the glass collected — no matter its quality. Some if it is repurposed into recycled granular glass cullets, which are used in place of concrete in road beds and pavements and in fibreglass and foam insulation. Krysteline Technologies wanted to modernise their product packing line by reducing manual labour and automating the process. Here’s how Webster Griffin helped them.

The Refining Process

The quality of processed material is determined by the feedstock quality, moisture content and installed technology. The Krysteline strategy is to diligently consider the feedstock and provide the technology which ensures the client’s expectations are met. Product quality can range from aggregates to fully purified sands and powders for filtration and abrasives.

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Why Was A Form Fill Seal Machine Most Appropriate For Krysteline Technologies?

Webster Griffin recommended the client install an automatic Form Fill Seal (FFS) bagger and robot palletiser. The FFS bagger would accommodate bag sizes ranging from 5 to 25kg and a maximum empty bag width of 500mm. It would have rubber lined forming tubes to ensure the machine is well suited for handling dusty products.

An existing feeding system would move product into the bagger through a mild steel surge hopper with level controls. This would ensure the bagger received enough product to maintain the required packaging rate.

A film centering device would properly centre and form each bag before a two stage dosing system filled it. A net weigher including an electronic load cell weighing system would ensure each bag was filled to the correct weight. It’s weigh-pan would have a quick-release side door to make cleaning easier and more efficient.

What Challenges Did Krysteline Technologies Pose To Webster Griffin Pre-Installation?

Krysteline Technologies wanted an automated, high throughput packing line that would work around the clock to meet their production targets.

It would need to package 16 tons of product hourly into 25kg PE bags — accommodating other bag sizes in case of last minute demands for different bag shapes and designs. The packed bags would also need to be palletised and ready for transportation.

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An electric height adjuster at the bag support saddle would adjust the bags according to size. Each filled bag would be micro-perforated to remove excess air and create a square and tidy package. After each bag was heat sealed, a belt conveyor would move it and a bag turner and height adjustable flattener to rotate the bag and compact it ready for delivery.

The heavy duty palletiser was equipped to fill an empty pallet standard magazine of 14-15 empty pallets. The robot was equipped with teachable software and 100 different existing palletising programmes.

It was also equipped with a programmable thermal printer to add barcodes and text on the side of the filled bags. The system could be commanded via a PLC touchscreen. A mechanical fence and interlocked access door installed around the bagging zone would keep out unauthorised personnel ensuring safe operation.

How Did Krysteline Technologies Benefit From The Installation?

Webster Griffin installed the system at the client’s facilities roughly 13-14 weeks after they ordered it. They also dispatched engineers to the site to monitor the installation and test it. It immediately provided a throughput of 640 bags an hour — which is higher than anticipated.

Being automated, the system allowed employees to focus their attention on other production tasks. Its dosing accuracy reduced product waste and inaccurate weighing. As it could accommodate different bags, the client could also respond to customer demands immediately, giving Krysteline Technologies an edge over their competitors. 

The palletiser also provided many benefits. By adding a label and barcode to each bag it helped them improve their product traceability. As the palletiser also produced neatly stacked and fully loaded pallets it also made international exportation easier and more efficient.

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To Find Out More
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