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Kensal Exhibits a Working Conveyor at the 2018 PPMA Show

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At this years PPMA show, held 26th -27th September, Kensal decided to exhibit something a little different for the standard static display, or machine in a box exhibits shown by others, and construct a scaled down bottling line.  The challenge was to display the key components all within the confinds of a 12mx4m stand. On display we squeezed in a magnetic matt top conveyor bend, a pressureless combiner, accumulation table, roller, modular, slat and LPB conveyors, running 500ml PET bottles, kindly supplied by Lucozade Ribena Suntory.  To prevent upsetting our neigbours we limited the speeds though the S7 Siemens PLC and 17 SEW  drive motors to approximately 400 bottles per minute, but in the real world and with longer sections speeds of up to 1200 Bottles per minute are perfectly achieveable

Not content with the bottling line, we felt that the area in the centre could be utilised, so we manufactured a pack divider, suitable for seamlessly seperating boxes, packs or cases.

Contact Kensal Handling Systems to discuss your application requirements

Kensal Triple Robotic Palletiser System

We supplied a multi robotic palletising systems for a major UK food manufacturer, this was built and pre-tested at Kensal's manufacturing and assembly plant in Luton to enable a fast installation on site. The system incorporates 3 large Kuka Robots and Kensal's stainless steel conveyor for packs, empty and full pallet handling.

Kensal manor bakeries 104The robots had a custom in-house designed vacuum head, to gently and accurately lift the display ready packs onto the pallets without any damage.

The custom head, which is critical to all robotic applications, was designed to be able to lift in 9 independently controlled zones each with its own feedback system to ensure full control whether lifting a single box, a row or a complete layer.

Kensal were also responsible for the six infeed production lines and the six exiting pallet lines, marshalling the exiting conveyors through a stretch wrapper into a buffer area.  The ability for each robot to handle two full production lines resulted in significant cost and space saving

This is only one of many Robotic systems we have integrated into the food and drinks industry over the past 14 years when we first used them.


Kensal Bespoke Storage System

Kensal Handling Systems have installed a major contract with a global manufacturer of automotive catalytic converters.


thumb Bespoke SystemsThe storage system, comprised of two triple tiered bi-directional conveyors, which gently handle the catalysts as part of a buffer system, loaded by robots, it is used to optimise their continuous production.


Kensal specialise in the design, planning and implementation of various bespoke systems to suit the broad range of modern manufacture


Another Lucozade Ribena Suntory Order

LRS 2a 2b accumulationKensal Have now completed the final phase of upgrades to two main filling lines for Lucozade Sports.  We have installed conveyors from the filler all the way through the sleeving process to the shrinkwrappers and onto the palletisers and beyond.  As the photograph shows, there were significant areas of loose bottle accumulation to ensure continuous production, even in the event of sleeve changes etc

The lines have required numerous different conveying products to be used to optimise the layout and handling at the different stages of production. 

One interesting challenge was transporting the shrink wrapped packs from one building to another, requiring over 400metres of conveyor of different styles to handle height changes, pack accumulation etc.


Sweet Production Lines Near Completion

Kensal are nearing final commissioning of multiple production lines for a premium brand of Dessert manufacturer.

With numerous lines, for handling the product at different stages of production and integrating a diverse range of machinery, Kensal were responsible for ensuring the tasty dishes made it safely around the entire production system.

Noble Case palletising










 We handled the product empty, filled prior to sealing, sealed, frozen, wrapped into individual packaging, into cases and then finally palletised.


To integrate all of the equipment on the production lines, Kensal supplied a broad range of conveyor types to suit the product being handled at each stage including six complete robotic cells and various other specialist pieces of equipment.  The whole system is controlled by multiple PLCs that comunicate with each other and a central production control system.


UV Tunnel

UV Tunnel 1

Kensal have just completed installation and commissioning of a UV system for sterilising the outside a a range of containers transporting product from low care to high care.  The cotainers were up to 500 wide and 500mm high.

This has resolved a common problem found in high hygiene environments, where the product inside the containers is sterile but during transport, the outside is exposed to a range of bacteria that customers do not want to cross the care threshold.  The power and speed of the system allows for up to 4 log 

Due to the high power of the UV light system, Health and Safety issues were paramount and independantly tested to ensure that the system is safe.

The design of the main UV chamber allows operators to see inside, through a UV proof  window.

To assist in maintenance and allow access to the UV lamps, which completely surround the product as it passes through, the lamps are mounted on a pull out track system. 

The fully interlocked guarding and floor is removable to allow for easy cleaning.






Contact Info

Kensal Handling Systems Ltd
Luton, Bedfordshire, UK
Tel : +44 (0) 1582 425777
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