A Clean Sweep For New Co-Packing Facility

A major global logistics company's state-of-the-art contract packing facility at Manton Wood in Worksop is reaping the benefits of an impressive new turnkey packaging line. High-tech shrink wrapping machinery, box taping equipment, pallet wrappers, packing tables and an intuitive network of conveyors were installed as part of an impressive joint project delivered by our team alongside warehouse automation specialists Breathe Technologies. The integrated solution was specially tailored to a new production line the logistics multi-national had commissioned for the packing of domestic cleaning products.

As one of the world's largest logistics businesses, our customer is directly responsible for the packing and distribution of hundreds of popular household products via contracts from major leading brands and manufacturers. Their warehouses cater for hugely varied products from the food, pet food, e-commerce, personal care, DIY and cleaning sectors to name but a few. However, the newly-built Manton Wood site is earmarked especially for personal care and cleaning products, wrapping items such as toothpaste, bottles of peroxyl, drain unblocker and air fresheners, many in twin packs with cardboard trays. The opening of this new distribution centre in 2020 necessitated a complete packaging solution capable of handling these products in varied collations, with a separate dedicated BAMA compliant line for aerosols.

As the UK leaders in flexible wrapping solutions, we have supplied multiple sites for this customer across the UK for many years, acquiring a comprehensive understanding of their high standards and unique requirements. Alongside Breathe Technologies, who provide smart warehouse technology solutions and with whom we have worked collaboratively on previous projects, we were ideally placed to assist the Manton Wood site as their production ramped up. For all of the display packaging applications, our robust and reliable Flexo X high-speed side sealer with shrink tunnel was ideal. And for the firm’s transit packaging applications, our SVA60-35 side feed sleeve sealing line and tunnel was installed, boasting a number of enhanced safety features specifically for aerosols. Following the shrinking process, boxed products were diverted through a number of our Robotape box taping lines before two automatic turntable pallet wrapping machines readied the loads for the final distribution channels.

An advanced network of powered infeed and outfeed conveyors harmonised each stage of the packaging process, supplied and installed by Breathe. The high-performance belt conveyor modules were installed across 15 packing lines allowing up to 50kg of product per meter load and integrated with various third-party equipment including heat shrink and bundling machines. In addition to the conveyor system install, Breathe also provided the role of principle contractor under CDM, both the controls hardware and software, integration and project management for seamless delivery of the co-packing line.

To maintain the packing operation, we included a full package of engineering support. A 24-hour breakdown response guarantee, extended warranty, six additional service contract visits, unlimited operator training and discounted spare parts supply sealed the deal.

Mark Hayes, project manager for the logistics firm said:

YPS and Breathe Technologies worked tirelessly to implement and fine-tune this co-packing line so we could be operational at Manton Wood right on schedule. We’re pleased with the flexibility the systems offer us to run a diverse catalogue of products in differing formats for our customers.

Our sales director Jonny Braithwaite added:

It was a pleasure working on this project with Breathe Technologies. This customer's brand is synonymous in the co-pack world with quality and reliability, so any solution we put forward had to meet these high impeccably standards. I’m delighted that we have achieved that by successfully delivering a robust, reliable and safe system and a professional finish across all wrapped packs.

Marcus Uprichard, head of sales & partnerships at Breathe Technologies finished:

We have a long-standing relationship with this business, providing dynamic technical solutions for the retail, manufacturing and logistics sectors. Working alongside YPS to deliver this integrated solution has ensured the new co-packing site is able to provide seamless complex contract packing programmes as efficiently as possible for their customers.