Alway Loughborough, a leading engineering and fabrication business established in 1985, was tasked with designing, manufacturing, and installing a state-of-the-art bakery conveyor line for a well-established bakery. The project aimed to enhance the bakery’s operational efficiency, processing capability, and overall productivity in producing loaves of bread.
The client is a renowned bakery known for its family focus and passion for baking. With a strong market presence, they sought a solution to streamline their production process, accommodate increasing demand, and reduce maintenance downtime.
The conveyor line was required to extend over 270 metres in length and include a half-metre incline to facilitate elevation increase in the factory.
A future-proof, efficient, and robust solution was required to process up to 2000 loaves per hour, enabling the bakery to meet increasing demand while maintaining high quality. Furthermore, the conveying line needed to be easy to clean and maintain.
The project needed to be delivered at pace within a fast-paced construction schedule.
The conveyor line was meticulously designed to meet the bakery’s specific requirements, with a well-designed framework and leg design to accommodate the factory layout and incline. Tests and trials were conducted, including producing prototypes to ensure the final conveying solution met the project scope.
The conveyor incorporates removable sections to enhance maintenance efficiency, providing easy access for quick servicing. The robust framework ensures protection for critical components, contributing to the overall durability of the conveyor line.
Additionally, it features various operational enhancements, including brake units that guarantee precise placement of bread tins into the oven, a magnet conveyor to facilitate accurate distribution of dough into the bread tins with minimal wastage, and a diverter conveyor that optimises operational flexibility by managing which lines are in use.
Furthermore, particular focus was placed on the material specification, specifically in the plastics, bearings and belts used to ensure they could accommodate the heat dissipation requirements.
Alway’s engineering team collaborated closely with the client to understand the specific layout requirements and operational needs. The design process included:
Site Assessment
Evaluating the existing bakery layout to provide a solution that would integrate seamlessly within the factory layout.
Concept & Trial
Develop a tailored solution that aligns with the bakery’s workflow and production goals. This was supported by fully operational prototypes.
Feedback Iteration
Incorporating client feedback at various design stages to ensure all specifications were met.
Magnet Conveyor
The magnet conveyor line was designed to hold tins in place precisely and ensure minimal wastage during dough distribution. This feature enhances the filling accuracy and optimises the use of raw materials.
Diverter Conveyor
The diverter conveyor allows for the control of operational lines, providing operational flexibility. This flexibility minimises downtime, enabling the bakery to maintain production during servicing and repairs.
Heat Dissipation
Alway incorporated heat-resistant materials and innovative belting designs to address the challenges posed by high-temperature environments. These features ensure effective heat dissipation, preserving the integrity of the bread and the conveyor system.
Guy Satterhwaite, Lead Design Engineer for Alway, said, “This large-scale conveyor line project posed many challenges. Our goal was to provide the client with a future-proof, robust and efficient solution. The chassis and framework for the conveyor goes above and beyond the industry standards in terms of finish and strength, whilst the specified operating components are some of the best in the industry. The project’s successful completion was achieved through a collaborative team effort by everyone involved. I invested quality time working with the client and our manufacturing team to overcome challenges and further refine our solution.“
The installation of the conveyor line was executed within a tight timescale, reflecting Alway’s commitment to delivering industry-leading standards. Key steps included:
Site Preparation
Ensuring the bakery was ready for installation with minimal disruption to ongoing operations.
Installation
Our expert, “Safe Contractor” approved onsite team installed the conveyor system, integrating it with existing machinery safely and efficiently.
Testing
Comprehensive testing was conducted to validate the functionality and efficiency of the conveyor line before handover.
Reece Taylor, Divisional Operations Manager for Alway, said, “This project demonstrates Alway’s capability to provide small and large-scale solutions to a diverse range of industries. We are pleased with the client’s feedback on the quality and functionality of the bread tin conveyor.“
The new conveyor line has successfully increased the bakery’s production capability to 2000 loaves per hour, meeting the growing output requirements without compromising quality.
With its robust framework, our tin conveyor provides superior protection for key components. Removable sections allow for quick maintenance, significantly reducing downtime.
Including diverter and mag conveyors have enhanced the bakery’s operational flexibility, enabling seamless transitions between production lines and reducing material wastage.
The successful delivery of this bakery conveyor line by Alway Loughborough is a testament to our design, engineering and manufacturing capabilities, which have drawn on the extensive knowledge and experience that have defined our company since its establishment in 1985. This project enhances the bakery’s operational efficiency and sets a new benchmark for future endeavours within the industry.
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