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Case Study 1: Fully Automatic Robot Packing System.

This system was designed using a Robot to erect and bottom seal Cardboard Boxes from a flat pack box magazine. The same Robot then collatates the two different products running on the 2 lines and using a state of the art Vacum Head and itelegent Robotic Controller loads the product  into the erected boxes on the 2 loading stations. The filled boxes are then top sealed, stacked and transported via a fully automatic conveyor system through a curing oven and then to the warehouse to be dispatched. The system was designed to handle various formats ranging from 9 to 96 products per box all selected from an operator touch screen.

ROI: For a cost of £370,000 this company was able to de-man the line, losing 4 operatives per shift from the line. The solution paid for itself within 12 months.

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Case Study 2: Special Conveyor Applications
Potting Conveyor
Problem: The customer had an operative manualy moving product to a heater station then to a cooling station. There were issues wit the curing times as the operator did not always move the units at the correct times.

Solution: GPS designed a system to heat and then cool the product over a given time while transfering the product to the next station via a conveyor which traveled at a speed of 1 meter per hour.  This conveyor cures the  electronic encapsulation resin for electrical components, the customer has achieved zero defects since installation of the system.

 ROI: For a cost of £11,000 this company was able to de-man the line, losing 1 operatives from the line. The solution paid for itself within 6 months.

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Case Study 3: Tub Lid Applicator
Lids
Problem: The client had a filling system for margarine but required an atomated systen for the lids running at 100 tubs per minute.

Solution: GPS designed a fully automatic servo applicator system that was retro fitted to the existing filling machine and required no operators. It also had a fully automatic sytem to load the magazines .  This project far exceeded customer expectations

 ROI: For a cost of £78,000 this company was able fully automate the lid application and introduce a more cost effective lide, losing 4 operatives from the line. The solution paid for itself within 6 months.

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Case Study 4: Fast change line guide
Lane Guides
GPS have developed a mechanical lane change system allowing automated line set up for filling lines via PLC control.  Typically 6 seconds change over is available.
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Case Study 5: Mid Conveying Product Orientation
Orientator
GPS have developed a revolutionary new system for orientating products along a conveying line by utilising a vision system.

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Case Study 6: Existing Filler Twin Servo Scoll

A Twin Servo Feed Scroll system was designed and installed on a customers existing 4 head index filler. This system enabled the customer to run new and difficult to handle products through the filler originaly designed for simple standard products. Once installed the additional benefit were vastly improved speed, reliability and the overall gain was in the region of 15% productivity.

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Case Study 7: Fully Automated 8 Format Capping Machine
A fully Automatic Capping System was designed to handle 8 different formats varing from and including a 30ml test pot upto a 1 litre contaner and also a 500ml hand pump container. This system consisted of a Cap hopper and elevator conveyor to automatically feed caps to twin vibratory sorters in accustic enclosures to give correct cap orientation. The caps are then feed onto a single cap feed conveyor into a holding cassette ready to be applied.  A servo driven indexing star wheel is used to accurately position the prefilled containers.The cap is then applied using a servo driven applicator head. Due to the inteligent design of the machine it is possible to carryout a full product size change in 4 minutes.  
http://www.youtube.com/watch?v=OA3lW-n97k4

Case study 8:Pharmaceutical Company

Problem: Press on and Pump Caps were manualy assembled onto the containers. This was a labour intensive process and a commercially unacceptable position due to the manning needed.

Solution: GPS designed a fully automatic system that required no operators and had achangeover time of 4 minutes from one product to the next. 

 ROI: For a cost of £120,000 this company was able to de-man the line, losing 4 operatives from the line. The solution paid for itself within 6 months.

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Case study 9: Food Company

Problem: This food company were introducing a new unstable container, which their filling lines were not capable of handling effectively due to the shape of the container.

Solution: After detailed analysis GPS fitted a modification with servo feed scrolls. This enabled the product to run down the filling line without the cost of additional lines.

ROI: For the cost of £30,000, the modification returned a 20% improvement on their honey line, which is the largest part of their turnover.

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Case study 10: Cosmetics Company

Problem: Pump Cape were manualy destacked by hand by 2 operators as well as a Pump diptube applicatoer screwed on by hand.  

Solution: GPS provided the company with a pick and place pump destacker with layer tray removal and also a fully automactic dip tube pump applicator with variable torque settings.

ROI: For a cost of £135,000 the application paid for itself in 6 months and they could also run additional products down the line, which gave them maximum flexibility.

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Case study 11: Injection Moulders

Problem: This company had a production line that was very manually intensive and a lot of the the employees were suffering from Repetitive Strain Injury.

Solution: GPS designed and manufactured a semi automatic handle applicator machine to the line.

ROI: For a cost of £25,000 the businesses returned an improved health and safety record with far less RSI problems, resulting in less sick days.

We have a vast experience of building full machines and thrive on the challenge of pioneering a solution to a non-standard application.