Modular solution creates efficient packaging success for new drinks packs

When Aston Manor, the cider-led beverage company, created a new product, they used modular elements of an existing packaging line with new equipment to create the ideal packaging solution for a new rework operation. 

Paul Clifford, Aston Manor’s Manufacturing & Engineering Director, looked to packaging suppliers Yorkshire Packaging Systems (YPS), who had previously supplied equipment to them, to advise on the most appropriate potential equipment options.

The challenge

“Across Aston Manor, we strive to be efficient and sustainable in everything we do.  I discussed with YPS how to incorporate under-utilised equipment, that we already owned, into the new line,” explained Paul.

“The modular nature of the equipment we owned from YPS could be easily combined with new machinery to create a full packaging line for the new product.  Throughout the discussions, YPS sought to find the best solution for our new requirements.”

The new product in question features a 24-pack of canned drinks, shrink-wrapped onto a tray for stability.  The new rework operation allows Aston Manor to take multiple SKUs and sort into a mixed SKU single case.  Previously the operation was outsourced and the YPS equipment had been used to wrap a different product altogether. 

The finished pack sizes were fairly similar, so the ULMA heat shrink tunnel from the previous line could be included in the new line with minimal re-configuration.  Aston Manor purchased a new sleeve wrapper with an integrated inline infeed to cater for the new product.  The result?  A new line with the same tunnel coupled with a new sealer.

The solution

YPS trialled and tested the Aston Manor products on the proposed line before supply of the new shrink-wrapping equipment.  The trials demonstrated that the new line could more than cope with the desired throughput levels.  The line was then installed by YPS engineers and signed off in situ.

The flexibility of the new inline sleeve sealer should prove a great investment for the future, able to easily handle further product innovations or many of the products and collations from Aston Manor’s wide range. 

Switching between products or collations only requires a few simple tweaks, such as altering the height-adjustable sealing jaw, with no requirement to change any machine parts, resulting in swift changeovers with minimal downtime.

The result

“This investment delivers additional packing capacity with flexibility that could prove invaluable as our business moves forward,” commented Paul.  “We’ve been happy with the equipment, service and support from YPS in the past and are extremely pleased with the solution they put forward this time.”

Supply of the new packaging line includes a YPS Service Contract, which is standard for all equipment supplied by YPS.  Service and maintenance work is carried out throughout the UK and Ireland by YPS’ own team of engineers.

“Our focus is always to help our customers to find the ideal solution for their packaging needs,” stated Glyn Johnson, MD of YPS.  “For Aston Manor, it was clear that we could include part of their previous line into their new line without compromising on performance, so this resulted in the most cost-efficient solution for them.”