United Petfood palletiser integration: doubles capacity

This case study explains the United Petfood palletiser integration at the Hoogeveen facility. United Petfood Nederland ALU B.V. faced rising demand for premium pet food. Therefore, they chose a second production line with a Qimarox Highrunner palletiser. Westover handled integration. By reusing proven modules, the solution remained compact and cost-efficient. Moreover, there was no interruption of the existing line.

Customer Background and Context

United Petfood Nederland ALU B.V. produces high-quality cat and dog food. In 2007, they installed a Qimarox palletiser in a crossrunner layout. This design allowed future expansion. Over time, demand grew steadily. Consequently, planning for a second line became urgent. United Petfood re-evaluated all suppliers. They needed a palletiser that matched or exceeded existing throughput. They also required adaptability for new product formats.

Selection and Rationale

Although uniformity was desirable, United Petfood compared multiple vendors. Key factors included throughput to avoid bottlenecks. They also needed a minimal footprint in an active facility. Since Qimarox now supplied components, a reliable integrator was crucial. Westover was recommended based on past collaborations. Therefore, the Qimarox Highrunner palletiser paired with Westover was chosen. This combo offered modular design and proven performance. It also fit the patented crossrunner palletising concept.

Solution Overview

The Highrunner palletiser uses a layer forming module and a layer depositing unit. It also includes a pallet lift and the Sheetrunner module. The Sheetrunner inserts stability sheets between layers. In addition, the crossrunner palletising system handles both empty and full pallets on one conveyor. Pre-programmed stacking patterns are available. However, new patterns can be created easily. Standard Qimarox modules controlled investment costs. Meanwhile, spare-part inventories stayed lean. Westover managed mechanical installation, control integration, and commissioning.

Implementation Journey

Planning required careful coordination. The original line had to remain operational. Westover led logistics and platform setup. They scheduled installation windows during live production. Mechanically, the Highrunner palletiser tied into existing conveyors. These fed the layer forming and depositing modules, pallet lift, and Sheetrunner. Control logic handled product size variations and stacking patterns. Rigorous tests validated throughput and load stability. Therefore, iterative tuning ensured consistent results. As a result, the original line ran uninterrupted. The new palletiser went online seamlessly.

Operational Workflow

Products arrive via the inbound conveyor at the layer forming unit. Orientation adjustments occur automatically when needed. Next, the layer forming mechanism assembles items into the desired pattern. Then, the layer depositing unit secures edges and places layers on pallets via the lift. If extra support is required, the Sheetrunner inserts a stability sheet. Meanwhile, the crossrunner system continuously moves empty pallets in and full pallets out. Thus, stretch-wrapping or staging follows immediately. This continuous flow allows rapid changeovers. Moreover, it maximizes flexibility without downtime.

Results and Benefits

Thanks to this “United Petfood palletiser integration,” throughput in Hoogeveen doubled. Installation occurred without halting the existing line. Now, the new line runs continuously. It offers quick product changeovers. The compact crossrunner layout saved floor space. Using standard modules kept investment in check. Spare-part management remained simple. Rapid switching between preset or custom stacking patterns supports varied packaging. The modular setup allows easy future expansions. Consequently, efficiency and reliability increased. The return on investment came sooner than expected. Strong collaboration between United Petfood, Qimarox, and Westover was key. They addressed challenges promptly. This success now leads to talks about further projects.

Customer Feedback

United Petfood praised the outcome and process. Linda Frens, Operations Manager at United Petfood Nederland ALU B.V., said: “The cooperation with Qimarox and Westover was very positive. They provided thoughtful, flexible, and pragmatic solutions.” This positive feedback reinforced trust. Moreover, it sparked discussions on future initiatives. The same modular, customer-focused approach will guide those projects.

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