When Birds Eye planned to centralise their Automatic Palletising systems at Lowestoft, UK, they asked Worldwide Services Ltd to design the system and to Project Manage the manufacture, Installation and Commissioning.

Engineers at Worldwide Site Services knew exactly what was required to centralise the Palletising while maintaining production in the existing Packing Hall.

New Conveyors were supplied to Link Production with the New Centralised Palletising operation.

All production lines were equipped with bespoke pack inspection and reject systems and post packing vertical elevators to raise all products to high level ready for crossing a bridge into the Palletising Area in the Warehouse building.

4 transportation conveyors merged onto 1 accumulation conveyor to allow a single conveyor to pass through an existing bridge, which connected the production Hall with the Warehouse.

A new Intralox DARB sorter was installed in the Palletising Hall to direct the cases of Frozen fish and Potatoe Waffles product to the correct Palletiser. An Existing Low-Level Palletiser was relocated and linked to the sorter.

An Existing Robot Palletiser was relocated and linked to the sorter. A new Robot Palletiser was installed.

The Robot Cells, were designed to be compact in size, due to the relatively small area of the Centralised Palletising centre. Yet each cell included an Empty Pallet dispenser, integral pallet conveyors, a layer sheet dispenser and a row forming conveyor.

The Robots were programmed to stack pallet loads of Frozen product in pallet patterns designed to maximise numbers of cases per layer and layers per pallet.

Safety was paramount in the minds of the WSS Engineers and the Robots cells were equipped with Perimeter Safety Fencing and electrically interlocked Access Gates to fully comply with EU legislation.

The Installation was completed on schedule and thanks to careful and considerate project planning there was minimal disruption to Birds Eyes production.

In the unlikely event that one of the relocated Palletising machines broke down during production WSS installed an emergency Hand Palletising station just to make sure production would never have to stop.