Supporting automation with Gough Engineering

In today’s rapidly evolving industrial landscape, automation is key to improving a production system’s performance in key areas such as increased capacity, enhanced efficiency, reducing labour costs and ensuring consistent product quality. Indeed, research by Aptean found that automated businesses see 30 per cent higher average growth rate than those relying on manual processes.

The spotlight often falls on sophisticated automation software provided by giants like Siemens. However, a crucial role of automated material handling in supporting these automated processes can be overlooked. The mechanical integration of value-adding forming processes can be improved through quality inspection, such as mechanical vibration screening, or by using product transfer systems that link and bridge key processes. Efficient transfer solutions, including screw feeders, vibrational feeders, and bucket elevators, can enhance these connections.

At Gough Engineering, our mechanical solutions seamlessly integrate other types of automated systems to optimise production workflows. Examples include the innovative Swinglink® Bucket Elevator system, the Gough Batch Sieve (GBS), linear vibratory systems (GLVS) and more. Let's look at some examples, below.

Enhancing automation scheme development

Gough Engineering’s capabilities include the design and implementation of vibrational feeders, moving product from A to B with consistent delivery feed rates to the next process.

The design of feeders are suited specifically to the application and considers particular factors such as product, product conditions, throughput requirements, feed/delivery type, depth of material etc. All these elements will determine the size, type and drives suitable for the feed requirements. Drive types can be common to linear feeders and Linear Vibratory Screens, where two sets of Out-Of-Balance motors are used as opposed to Electro-magnetic drives. Additional vibrational transfer solutions also include tubular designs instead of a tray and lid design.

Screw feeders are also a potential solution for moving product through inclination and can be an alternative to vacuum systems or even aero-mechanical designs. Each solution has pros and cons and are all judged on application and customer requirements.

Gough’s Swinglink® Bucket Elevators transport material efficiently with a patented, pendulum open bucket designs. Unlike traditional conveyors, our bucket elevators keep the product stationary in the bucket, minimising damage during transit and contained within an enclosed set of cabinet sections to remove any environmental pollution. This makes them perfect for handling delicate or high-value raw materials.

Our bucket elevators are particularly effective in scenarios where precise, reliable product transfer is critical to the automated process.

By incorporating Swinglink® Bucket Elevators into your production line, you can achieve seamless integration with multiple lines using selective tipping designs that deliver materials to either robotic packing systems or automated single-line packing solutions. The consistent and gentle handling of products provided by our bucket elevators supports the accuracy and efficiency required in automated packaging and processing lines.

arrangement with flanges for airborne particles and dust extraction solutions.

Supporting transfer meterage and robot packing

In automated manufacturing environments, precise control over product transfer distances (meterage) is essential.

Gough’s bucket elevators can offer exceptional flexibility and control, allowing for the customisation of transfer routes to fit specific production requirements. This adaptability ensures that products are delivered precisely where they need to be, supporting the smooth operation of automated systems, whether leading to big bag filling stations, end-of-line packing into small bags, or fully automated multi-bag filling systems.

Case study: Enhancing automation and air quality

Gough Engineering’s success in helping Charlie Bigham's, a premium ready-to-cook food producer, implement a flowing production line highlights the critical role of material handling automation. The Gough Batch Sieve (GBS) has supported and enhanced automation within the manufacturer's production processes.

Charlie Bigham's faced a challenge in maintaining high-quality ingredient screening without compromising air quality in their kitchens. Gough Engineering provided an innovative solution with an enclosed Rip and Tip sieving station. This not only ensured the purity of powdered products but also integrated seamlessly with their existing workflow:

1)   This custom-designed sieving station features several advanced components that demonstrate the synergy between mechanical solutions and automation. The Gough GBS Batch Sieve, which forms the core of the system, includes a vibratory sieve powered by a single out-of-balance motor.

2)   This motor generates the vibratory motion necessary for efficient and consistent product screening. This ensures that all powdered ingredients meet the stringent quality standards of Charlie Bigham's.

3)   The vibratory sieve's design also incorporates a bespoke, drop-in mesh system. This allows for easy access and quick cleaning, minimising downtime and maintaining production efficiency.

An integral part of the sieving station is the ATEX compliant dust extraction system. This system includes a fan-assisted dust extraction unit with reverse air jet cleaning. It uses pleated cartridge filters to capture airborne dust particles generated during the bag opening and dispensing phase.

The system expels the extracted air cleanly, meeting Health, Safety, and Environment (HSE) air quality standards. The enclosure is made of stainless steel, 316 grade for product contact areas and 304L for other areas. This ensures durability and hygiene, essential for food production environments.

A small Programmable Logic Controller (PLC) controls the system. This allows for adjustable timer functions for both the dust extraction and the compressed air filter cleaning cycle. This level of automation ensures that the sieving process operates efficiently and with minimal manual intervention.

The result? A free-flowing automated material handling system within Charlie Bigham's production line.

This demonstrates the vital role that robust mechanical systems play in complementing and optimising automation in diverse manufacturing settings.

Case study: Quality Control and Bagging Line

Gough Engineering’s capabilities to integrate different systems into one single source of supply was recently achieved for a major UK vegetable processing firm. They required a solution to help deliver product material (post drying), into a quality control check screen (ATEX certified) to allow only good product, then metal checked, to then flow into a small bagging system (weighed). The system needed to work on low volume, fine particles without product degradation.

In order to complete the necessary product transfer into the bagging line (post quality screen check), a Piab vacuum transfer system was incorporated, delivering a reliable product stream into the final gravity fall, metal rejection system and then onto the final automated bagging line.

This solution provided the following benefits for the customer:

1. Efficient transfer of good product checked by by particle sizes
2. Final metal checking equipment to meet internal quality assurance standards of final product
3. Automated weighing and bagging.
4. Auto bag sealing.

Working alongside Gough Engineers, the scope of supply was successfully installed and operational.

Contact us for tailored automation support

If you’re looking to optimise your automated processes with reliable mechanical solutions, Gough Engineering is here to help. Our expert team can help you design and implement cost-effective systems tailored to your production needs. Contact us at +44 (0)1782 567770 or fill out our online enquiry form to learn how Gough Engineering can support your material handling automation goals.