Bespoke System Engineering

thumb Bespoke SystemsKensal Handling Systems can provide bespoke system design for your specific application. From working with specialist PLCs to integrating with your existing manufacturing control systems, through all aspects of design and implementation.

The Case Study below give a flavour of the scope of the expertise and skills which we will bring into action to provide you with the solution you require 

Case Study - Accumulation Conveyor System for client J.M.

We received a requirement from J.M for a potential upgrade to their production line for Catalytic Converters.

There was a realisation that a new conveyor buffer between 2 exisiting Robotic production cells was required to balance the production and maximise line efficiency.

This J.M. product is unique, and their plant is one of only 3 in the world manufacturing this type of product.

Kensal Handling Systems was selected as a partner to develop a solution for the production lines. In selecting Kensal Handling Systems, J.M's were confident that we could provide fast, and cost effective solutions to the line problem.

J.M manufacture a range of Catalytic Converters for leading car and truck manufacturers, each having their own stringent manufacturing requirements.


Bespoke Systems2The units (or substrates as they are known) weigh up to 20kg each with dimensions from 80mm to 300mm diameter and 75mm to 304mm in height.

The project called for 60 minutes of accumulation between the 2 legs of the production process, but with space limited and access required to the robotic cells, the solution was not straightforward.

After several meetings, it was agreed that Kensal Handling Systems would provide a stainless steel frame with two sections each holding 3 tiered conveyors mounted above each other, with trays between the levels to prevent cross contamination.

Each substrate is manufactured using precious metals and the slightest damage requires the unit to be removed, the precious metals recovered and the substrate scrapped so gentle handling was essential and critical to the design to eliminate damage.

In addition, the units are loaded and unloaded automatically by robots and their exact position continuously monitored by a series of cameras. In order to meet this specification, Kensal Handling Systems designed the system with each level being stepped to permit access for the robot head.


Bespoke Systems1We selected a plastic modular chain with a moulded soft compound rubber face to allow maximum accumulation but ensuring  that each unit was held gently and securely for the time it was in transit.

The system operates by pre-loading the conveyors to 50% capacity at line start up and the conveyors then index in either direction to load or unload their product depending on the requirements of the production line.

Whatever buffer is left at the end of production is then unloaded to the second production leg at the end of the shift. The whole system is fully guarded including a roof for each section with 50% of the side panels fitted with clear polycarbonate windows for visual monitoring.

As a company we were able to demonstrate to J.M similar references that high- lighted our experience in materials handling solutions of this type.

This was sufficient testimony for J.M.to award the new contract for this bespoke handling system.

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