Market Sector:
PRINTING MACHINERY
COMPLETE MACHINE BUILD
ANC CASE STUDY
Re-engineering machines to meet compliance standards and customer expectations
When ANC Machinery needed to upgrade a successful range of blank separators to maintain its market position and meet customer demands, it faced a dilemma. The original manufacturer in Japan did not share the same need in its own domestic market. That’s when ANC’s Director, Gary Compton, decided to get its packaging converting equipment completely re-engineered in the UK by Warren Services Limited.
ANC Machinery, based in Cambridgeshire, is the export division of Kawahara Packaging Co Ltd, Japan. It has the exclusive rights to sell Kawahara’s successful TX Blank Separator series worldwide (outside of Japan). Its customers are packaging manufacturers of die-cut sheet-printed designs, for things like cartons, cards and labels, made from materials such as solidboard, paper and plastic.
The TX separators use pin-bed technology (literally a bed of 4000 strong pins) to press the packaging blanks out from the printed sheets and away from the surrounding waste material. Depending on the thickness of the substrate used in the printing process, they can cleanly strip between 200 and 1000 sheets every 30-seconds. They are a cost-effective solution for mid-sized companies looking to replace inefficient hand-stripping on production runs of between 5000 and 30,000 sheets.
Kawahara originally designed and manufactured the TX series in Japan and we began to build a strong European client base during the early 2000s. This created an aftermarket in spare parts, which for convenience and cost needed to be manufactured locally. That’s when I first contacted Warren to see if they could make the pin components, which they did successfully.
Gary Compton, ANC’s Director
Kawahara originally designed and manufactured the TX series in Japan and we began to build a strong European client base during the early 2000s. This created an aftermarket in spare parts, which for convenience and cost needed to be manufactured locally. That’s when I first contacted Warren to see if they could make the pin components, which they did successfully.
Gary Compton, ANC’s Director
THE CHALLENGE
About three years ago the company decided that, if ANC were going to continue selling in Europe and other western markets, they would need to upgrade the machines. They had been in production since the 1990s and needed a make-over of both functional and aesthetic features, which standards regulators and clients now increasingly expected. However, Kawahara didn’t have the same needs in its mature Japanese market.
“It was always going to be difficult for a Japanese firm focused on its domestic market to interpret and implement European safety standards,” explains Gary. “So instead, we shipped the existing TX machine to Warren and commissioned them for the upgrade. They took it apart, looked at how Kawahara had built it, and recommended a complete overhaul to modernise the electrical and electronic components.
CREATING NEW MACHINES FOR NEW MARKETS
“Warren’s advice covered the full wiring system, pneumatic system and control systems, including a new touch-screen HMI,” Gary continues. “They went on to design and develop all the hardware and software to meet (and often exceed) CE requirements. In short, they engineered a wholesale improvement to the functions on the original TX machine and the technology behind that functionality.”
Kawahara had traditionally used Mitsubishi for key components but Warren recommended Omron technology. Gary agreed to this as Omron were also willing to lend their compliance expertise to ensure the finished machine would meet the latest CE standards. Warren ensured that the machines also met UL and CSA standards, which has enabled ANC to continue selling in CE countries and offer the same version of the machine into the USA, Canada and other high-standard markets.
“Warren now takes the precision engineered metal shell of the original machine (which is still made in Japan) and kits it out with completely new electrical componentry to create our flagship TXS-1100. It then certifies that every machine meets all the safety standards for our core markets. Their User Experience designers also made the touch-screen instructions more intuitive, which makes it easier to train new operators.
“After using this process to upgrade the TXS, they have also engineered a similar transformation to the BMS-1100, which is a simpler separator that uses ram punch instead of pin-bed technology. We initially bought the basic machine from an Indian manufacturer and Warren designed and developed new electrical, pneumatic and hydraulic systems to meet appropriate western standards. The manufacturer in India then applied this compliance blueprint – so now when we buy a machine we ship it to Warren for thorough testing of all programming, electrical and mechanical elements before shipping out to our customers.”
WARREN DEMONSTRATES ITS DESIGN FOR MANUFACTURING EXPERTISE
They did that from a blank sheet of paper – we hadn’t even asked for it but I’m delighted with the result. It really demonstrates their ability to think more widely about their clients’ needs, to analyse problems and create innovative yet viable (cost conscious) solutions.
Gary Compton, ANC’s Director
They did that from a blank sheet of paper – we hadn’t even asked for it but I’m delighted with the result. It really demonstrates their ability to think more widely about their clients’ needs, to analyse problems and create innovative yet viable (cost conscious) solutions.
Gary Compton, ANC’s Director
As well as upgrading the TXS and BMS, Warren has developed two ancillary pieces of equipment for the TXS from scratch. “We had an idea for an unloader, which would gently lift the printed blanks off the pin-bed,” explains Gary, “but Warren developed the entire system based on just our outline. They then went on to develop a completely new style of affordable feeder that improves efficiency and is now on the market.
“The original feeder was a bit clunky but Warren’s new feeder delivers the sheets in perfect alignment onto the TXS. They did that from a blank sheet of paper – we hadn’t even asked for it but I’m delighted with the result. It really demonstrates their ability to think more widely about their clients’ needs, to analyse problems and create innovative yet viable (cost conscious) solutions.”
WARREN IS EVOLVING TO MEET THEIR CLIENTS’ CHANGING NEEDS
When I first started working with them, I considered them a competent metal component manufacturer. However, I’ve come to realise they have far more depth of experience and breadth of resources; and can now offer high quality electrical and mechanical engineering, including Design for Manufacturing services.
Gary Compton, ANC’s Director
When I first started working with them, I considered them a competent metal component manufacturer. However, I’ve come to realise they have far more depth of experience and breadth of resources; and can now offer high quality electrical and mechanical engineering, including Design for Manufacturing services.
Gary Compton, ANC’s Director
Gary has observed a change in Warren over the years. “When I first started working with them, I considered them a competent metal component manufacturer. However, I’ve come to realise they have far more depth of experience and breadth of resources; and can now offer high quality electrical and mechanical engineering, including Design for Manufacturing. I’m also impressed with their ongoing investment in their people, particularly apprentices, which is evident in the skills and enthusiasm of their employees.
“The team who work on our projects also visit our clients around the world to carry out machine installations and deliver training in operation. I wouldn’t let them do that if I didn’t feel confident in their ability to represent us professionally. They are keen to learn, with a drive to succeed.
“This just reinforces our manufacturing and business relationship with Warren. They enjoy the challenge of designing and building complete machines and we get marketable machines, which we could not have achieved without them. It is a genuine manufacturing partnership that has been going for seven years and,” concludes Gary, “we hope it continues for many years to come.”
Report by Huw Sayer at Business Writers Ltd for Warren.
