—SOLUTION

Robots help bring high quality hand-craftedceramics production back to Stoke

An automated production solution built byABB Authorised Value Provider The

Automated Technology Group (ATG)featuring four ABB robots is helping a Stoke-based ceramics producer to produce highquality flagons to a hand-crafted finish. Usedas part of four production cells, the robotshave helped to increase output and reducescrap product by helping to speed up flagonproduction whilst ensuring improved qualityand consistency.

Originally founded in 1810, Wade Ceramics currentlyoperates two production sites, with its site at BessemerDrive in Stoke specialising in the production of flagoncontainers used by several premium-brand alcoholicspirits manufacturers.

The company produces up to 80,000 flagons a week,including both refillable and non-refillable versions. Aswell as standard bottle designs, it also producescontainers to its customers’ specific requirements, withpast and current designs including fish, dogs and evenmermaids.

Just like any hand-crafted product, production of theflagons is an intricate process. Every flagon passesthrough multiple stages, starting with it being cast in clayand ending with decoration and inspection of the finalglazed product prior to packaging and despatch. Everyflagon is fired twice in the company’s two kilns; first afterthe casting and fettling stage and again after theapplication of the coloured glazing that gives each flagonits distinctive finish. At every stage, each container needsto be produced to the tightest possible tolerances toensure it meets the company’s strict quality standards.

“The flagons we produce need to reflect the values of theluxury brands we deal with,” says Stuart Shickell, Head ofEngineering for Wade Ceramics. “Even the slightestimperfection, whether it is the width of a bottle neck orinconsistencies in the colour or glazing, can result in oneor more products being rejected. As each flagon takesbetween 16 to 20 hours to produce, we were keen tominimise the risk of any problems occurring during ourmanufacturing process.”

process.”Newtech and then we went up to trial some

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As one of the last surviving ceramics companies inStoke, Wade Ceramics has been no stranger tochange. Originally offering around 50,000 productsin its portfolio manufactured across three sites, thecompany took the decision in 2000 to slim down itsproduct range to focus on decanters. In 2010, thecompany opened its current factory at BessemerDrive, with new machines and kilns. With increasingproduction demands, Wade Ceramics was keen tofind ways to improve production by furtherautomating its production line.

Installed in Christmas 2016 during a two-weekproduction shutdown, the automated systemsupplied by ATG has helped Wade Ceramics toincrease production and overcome several issuesthat had previously affected manufacturing outputand product quality.

One of these issues related to the positioning of theflagons prior to the first kiln firing. Flagons placedtoo closely together sometimes became fusedduring the firing process, resulting in them beingrejected for scrap.

This issue has been overcome by two robot cellsfeaturing ABB IRB1600 robots positioned on the in-feed to the first kiln. Each cell includes a visionsystem that locates each flagon as it is conveyed tothe kiln infeed and ensures it is correctly

positioned to prevent it fusing together with other

flagons during firing.

Another issue concerned inconsistencies inthe glazing around the base of the flagons.Applied as a powder coating, the glaze giveseach container its distinctive colour. To meetWade Ceramics’ high product qualitystandards, the glaze must be evenly appliedover the complete surface of every flagon.Previously, imprecise wiping after theapplication of the glazing powder wascausing some of the powder to be removedfrom the bottom of the flagons, resulting inan uneven finish.

Another issue concerned inconsistencies inthe glazing around the base of the flagons.Applied as a powder coating, the glaze giveseach container its distinctive colour. To meetWade Ceramics’ high product qualitystandards, the glaze must be evenly appliedover the complete surface of every flagon.Previously, imprecise wiping after theapplication of the glazing powder wascausing some of the powder to be removedfrom the bottom of the flagons, resulting inan uneven finish.

Now that the process has been automated, theprocedure takes 17 seconds. Newtech alsointegrated intelligent vision software into therobot cell to ensure that Boomf would get theperfect cut each time. According to JamesMiddleton, “There’s next to no wastage now andthat’s been a real benefit to the figures.”

—Robots help ceramicflagon manufacturerto achieve the best ofboth worlds byenabling highquantity productionwith a high-qualityfinish

Another issue concerned inconsistencies in the glazingaround the base of the flagons. Applied as a powdercoating, the glaze gives each container its distinctivecolour. To meet Wade Ceramics’ high product qualitystandards, the glaze must be evenly applied over thecomplete surface of every flagon. Previously, imprecisewiping after the application of the glazing powder wascausing some of the powder to be removed from thebottom of the flagons, resulting in an uneven finish.

To tackle this, ATG developed an additional robotic cellincorporating an automated ‘foot wiping’ system whichhelps to ensure precise and consistent wiping of theflagon base without removing the glazing powder. Thecell uses an ABB IRB2600 robot, which picks up eachflagon before wiping its base on a rotating cleaning matand then passing it to the conveyor to the second kiln.Developing this solution was not without its challenges,as Simon Miles, Applications and Proposals Manager –Systems Division for ATG explains:

“One of the biggest hurdles in developing the foot wipingcell was the need for the robot to be able to keep pacewith the powder glazing machine. To keep everythingperfectly synchronised, we needed to get the whole footwiping process done within a target Takt time of just 16seconds.”

To achieve this meant not only getting the products tothe robot from the glazing machine, but also making surethat the flagons were properly tracked when they arrivedat the robot and when they were arranged on the Kilnbatts located on the outfeed conveyor to the second kiln.

“Getting the process exactly right involved extensivetesting to arrive at the best set-up that would allow thecell to operate at the maximum speed,” says Miles. “Toenable the robot to stay within the target Takt time, thesystem tracks the position of the flagons as they enterthe foot wiping cell to allow the robot to squarely pick upthe flagon. Similarly, once the flagon base has beenwiped, the robot places the finished unit in a specificlocation on the kiln batt on the outfeed conveyor,enabling it to get into position to accept the next flagonas quickly as possible.”

An added complication was the need for the cell to alsoinclude an extra step required for non-refillable flagonvariants, which requires the robot to remove a temporaryshield plastic cap from the top of the flagon on exit fromthe glazing machine and prior to placement onto the kilnbatt.

The thorough testing carried out by ATG, together withthe accuracy and speed of the IRB2600 robot, means thatboth the foot wiping process and removal of the plasticcaps for non-refillable flagons can be comfortablyperformed within the 16-second window. Not only that,but the improvements delivered by the robotic foot-wiping process have meant that the flagon

reject rate has now fallen to just 1.5 percent.

The value of prior preparation

With Wade Ceramics running its production 24 hours aday, seven days a week, and with little spare spaceavailable at the factory, the complete automated system,including the four robot cells, had to be built and testedat ATG’s Northampton site. Working in conjunction withWade Ceramics’ engineering team, the system wasextensively tested to help ensure it would be ready foroperation with the minimum of disruption once installedat the company’s Bessemer Drive site.

“The complexity of this project, coupled with the need toget the automated system up and running as quickly aspossible once it was installed, meant carrying outthorough testing to ensure any problems were ironedout,” explains Simon Miles. “As a result, we were able toinstall everything on site within Wade’s two-weekChristmas shutdown in 2016, with production beingramped up as the system became fully operational.”

The company’s ability to maintain a high production

output without compromising the quality of its products

has given it a key advantage over its competitors, which

has been greatly enhanced by its use of automation. “The

methods that we use, together with the design of our

production process and the improved performance

achieved through our use of automation, enables us to

produce around 3.5 million flagons per year, more than

any of our competitors, whilst maintaining the very

highest standards of product quality,” concludes Stuart

Shickell.

automation and robots to boost our efficiency whilstmaintaining the traditional hand-crafted look andfeel of our products that is core to ourreputation.”

using automation and robots to boost ourefficiency whilst maintaining the traditionalhand-crafted look and feel of our products thatis core to our reputation.”

greatly enhanced by its use of automation.

“The methods that we use, together with thedesign of our production process and theimproved performance achieved through ouruse of automation, enables us to producearound 3.5 million flagons per year, more thanany of our competitors, whilst maintaining thevery highest standards of product quality,”explains Stuart Shickell. “We now have the bestof both worlds, using automation and robots toboost our efficiency whilst maintaining thetraditional hand-crafted look and feel of ourproducts that is core to our reputation.” The

confectionery company receive a large increase in ordersduring holiday periods such as Christmas and Valentine’sDay and need the resources in place to cope withfluctuations. Improving the process has also enabledBoomf to focus on other areas of the business such asexpanding delivery to more countries and looking at howother processes could be automated.

Jaz Gill informed us, “We develop a partnership with ourcustomers and look at where we can add value across thewhole of their production line. In Boomf’s case, we cancut the product perfectly, but they still have a challenge inmanually putting the product into boxes.” Over thecoming months, Newtech will begin trialling various usinganother ABB robot.

Further, using an IRB 1200 within a machine cellallowed Boomf to improve the health and safety at thesite. James Middleton was a victim of the manualprocess before the automated system was installed.He severed a nerve in the end of his finger whilstcutting a batch with a knife. Removing the humaninteraction from the cutting process removes the riskof such accidents and the employees can apply theirskills to other areas of the business such as operatingthe robot.

Overall, Newtech’s automated solution has been a realsuccess for the company. Ease of use is ensuredthrough the use of a HMI which enables staff tooperate the cell following simple training. Jay Gillinsists this means companies “won’t have to worryabout having an engineer on site.”

In terms of finances, Boomf were well aware that as astart up there would be a lot of cost. However,through investing in a robot the company has alreadyexperienced the benefits, and in their second year ofbusiness have grown at an astounding rate of 600%.James Middleton added, “It’s the benefits of havingthe robot that’s allowed us to grow that much in oneyear.”

Jaz Gill firmly believes that robotics and automation ingeneral is completely underutilised within food andbeverage. “It’s a whole culture change that we need tobring to our customers and their partners, for peopleto understand that the use of robotics, the use ofautomation, the intelligence, is not only far moreeconomic than it’ ever been and yields a fasterpayback, it’s incredibly easy to use,” he concluded.

When asked about what he would say to UKmanufacturers who were thinking of investing inrobotic automation, entrepreneur James Middletonwas encouraging. “I’d say go for it. The success thatwe’ve had with our robot speaks for itself. Anyinvestment in robotics is a great decision for anycompany that wants to insure their future in anincreasingly digital market.”

abb.com/robotics

—ABB Ltd.Milton KeynesUnited KingdomTel: +44 (0) 1908 350300

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