Webster Griffin "Flexible packing and palletising line for wood fuel pellets, boosts sales"

Bagging System for small and large paper and plastic bags from 2.5kg to 25kg, including bags with handles and special closures

Full Case Study on WTL Installation :

WTL's wood pellets are packed into 18 different bag sizes on the UP-1000	WTL's Wood Fuel Pellets

Smart Cat® woodbased cat litter is manufactured by WTL International Ltd, based in UK.   WTL were the first UK company to manufacture a softwood pellet for the cat litter market back in 1985.

The success of WTL’s wood based products is due to the growing demand for organic bio-degradable cat litters and fuel pellets.   Smart Cat® manufactured solely from softwood flour ensures quicker absorption than other brands and immediately controls odours within the litter – not surprisingly Smart Cat®  is now one of the leading brands in constant demand from the pet and veterinary wholesale markets.  

High Speed Packing – Reduces Unit Cost

	UP-1000 ideal for short high speed batch runs

The new fully automatic, packing and palletising line has enabled WTL to reduce their unit price and equipped them to target a larger market.

Increased demand from a wide range of clients and markets meant that WTL needed to find a high speed – yet versatile packing system, after a thorough market survey the Webster Griffin solution was selected on technical merit.

Initially the new high speed bagging line enabled WTL to cut back to one shift per day operation, however, the flexibility of the packing line soon resulted in a growth in sales volumes which meant they were back to two shift operation - packing double the volume and a four fold increase on the volumes they were achieving on their old semi-automatic sack filling station.

Flexibility the name of the game

	UP-1000 ideal for short high speed batch runs

At the heart of the new packing line is the UP-1000 bagging machine which can change from packing one bag size to an other “at the press of a button”, this makes it viable for WTL to produce small ‘non standard’ batches and short production runs on a wide variety of different bag types and weights.

Both the bagging machine and robot palletizer adjust for different bag sizes automatically, therefore, changing from a 3kg gusseted bag to a 25kg pillow bag only takes 2 minutes.   The UP-1000 will handle plastic or paper bags, pillow or gusseted bags.  

Paper bags are sewn across the top while plastic bags are heat sealed and a carrying handle is punched out on the smaller 3kg, 5kg, 7.5kg, 8kg, 10kg bags.   (A version of the UP-1000 is available for packing dry and damp pet foods, which can also handle self closing foil laminated bags).

Flexibility – right down the line

	Okura robot palletizer - 'all bag size changes are fully automatic'

Downstream of the UP-1000 is an Okura A1500 robot palletizer, equipped with a self adjusting pick-up hand it can palletise 32 different bag sizes and palletizing programmes.

Comment from WTL

The benefits of the new packing line are summed by Simon Thompstone, Sales Director at WTL

“The installation of the UP-1000 bagging machine and Okura robot provide us with the flexibility to pack from 3 to 25kg bags.

This flexibility and associated reduction in manufacturing cost has allowed us to win contracts and supply own label products to the supermarket, pet wholesale and pet superstore markets.

The new packing line has been a boost to our business because it enables us to offer competitive rates for packing our own brand or customers own brand labels”.

For further information please contact WTL Ltd or visit www.wtl-int.com

Video:

Layout Drawing of System:

	Project Specification
	Application: Versatile packing and palletising line Client: WTL International UK Product Packed: Woodbased cat litter and wooden pellets Bag Type: Paper and plastic Gusseted and non gusseted Handles made by the bagging machine (in plastic bags) Paper bags with pre-made handles - 3-25kg machine self adjusting Bagging Rate: 600-1000kg bags/hour System Comprising: Electronic net weigh scale UP-1000 bagging machine Interface conveyors Okura Palletising robot Pallet conveyors Guarding and control system Why Did WTL select Webster Griffin: Productivity - high speed bagging and palletising enables WTL to double throughput with fewer operators Efficiency - Automatic bag size changeover means no lost production or ‘down-time’ between changeovers Flexibility - Able to respond to customers orders immediately – whatever the bag size or type.  Auto changeover means negligible loss production when changing from one type of bag to another Economical - Able to pack small batches on demand, reducing stock levels and saving warehouse space.