ALS MECHATRONIC LTD

Overview
Address:
Unit 25
Park Farm Industrial Estate
Greet
Cheltenham
Gloucestershire
GL54 5BX
United Kingdom
Telephone:
01242 621315
Membership:
PPMA

ALS Mechatronic Ltd is a trusted supplier of bespoke factory automation and control systems to a variety of industry sectors including: food and beverage, pharmaceutical, rigid plastic container producers, dairy, waste to energy, material handling and packaged products. The company has particular experience in downstream automation and end-of-line systems including: product and container handling machinery, palletising, packing lines, automatic bagging and debagging and boxing machinery, vision inspection systems for measurement and contamination checks, state of the art robotics, conveyors and control systems/PLCs; designing from scratch and upgrading/replacing the out-dated.

ALS Mechatronic specialise in small control system projects through to ground-breaking innovations and complete turnkey automation, often delivering solutions when others say they can’t.

Established in 2002 and headquartered in North Gloucestershire, with offices in Texas, USA, ALS Mechatronic is advancing the processes and capabilities of a worldwide customer base, increasing their efficiency, quality and bottom line.

In 2021, the company was honoured with a prestigious Queen’s Award for Enterprise for International Trade.

Management Personnel

  • Operations Director Laura Steward
Products

Products Supplied

Bespoke Automation & Control Systems:
ALS Mechatronic are equally happy delivering single machine solutions and control system retrofits as we are designing and delivering the industry’s largest Alpine conveyor and turnkey solutions, comprising end-to-end machinery and control automation to support our customers’ exacting requirements.
Conveyor Systems:
ALS Mechatronic supply a complete line of conveyors to handle all your container conveying needs, including: industry standard stainless steel table-top, wash-down conveyors for filling room applications, rope, cable, slat top, belt, roller, eagle rope, mat-top chain and many others – all manufactured to meet and exceed local safety and regulatory requirements.

We’re also jointly responsible for the industry’s largest and most innovative Alpine conveyor, which has transformed Plains Dairy into one of the most high-tech, ultra-efficient dairies in the United States.

As the only economical, safe and hygienic method of enabling plastic containers to be moved hundreds of feet, conveyors are the main arteries of any production facility, of which they are not many we haven’t experience of. We can supply conveyors that support accumulation and surge (including vacuum assist to convey up inclines at higher speeds as well as stabilise top-heavy containers) during filling and/or packaging processes. Our use of cable drives with direct drive AC motors are always controlled with a variable speed drive to ensure ultimate flexibility, meaning whatever your conveying need, we’ll almost certainly have a solution to fit.

Rope Conveyor Services
One service that is always of particular interest to clients is our rope conveyor maintenance and renewal service. Our specialist equipment allows us to quickly carry out on-site cable repairs, replacement, re-sheathing and re-splicing.
Control Systems:
Our vast control systems capabilities range from small single drive control boxes to large scale plant control / SCADA systems – we can even engineer to enable control and performance updates to your mobile device and enable even greater control and flexibility of your operations. For example, machinery can run start-up procedures ahead of staff being onsite.

ALS Mechatronic are Rockwell Automation specialists as well as having in-depth experience with Siemens and B&R (now part of ABB). All our control design is carried out using Eplan. We are equally happy control panel building against customers’ existing drawings and providing essential control system updates, ensuring further years of life from your existing machine assets, as we are designing brand new control systems.
Vision Inspection:
ALS Mechatronic supply a vast selection of state-of-the-art, high-speed vision inspection systems from basic ‘Vision Sensors’ to 1000 parts-per-minute measuring and inspection systems and our barcode scanners ensure correct label-to-product matching every time.

Essential applications include:

• Identification of container faults and/or contamination
• Part presence on product/manufactured goods
• Circuit board inspection
• Component quality and measurement
• Bottle cap in place
• Correct label type and in position

Qdc Bench™:
The Qdc Bench enables container producers and their customers to proactively fault find and reduce waste, thereby ensuring complete quality control and a great reputation for high quality product.

The Qdc Bench uses state of the art technology including high grade optics and high resolution industrial cameras to capture and record bore and thread dimensions, these are essential periodic checks required during container production and filling process to ensure faults are quickly identified and that quality is assured.

Error is inevitable when you rely on the human eye for measurement.

The Qdc Bench replaces manual processes i.e. operators using a vernier and manually recording results on paper, which potentially introduces translation errors, data loss or results not being stored for future reference. With a lack of traceability, root cause identification becomes problematic, multiple people across multiple shifts may be conducting random quality checks with no standardised method of measurement.

Features and Benefits of the Qdc Bench:
• Material colour can range from clear to opaque and any container size
• Materials can be plastic, glass, or metal
• Measurements include Inner and Outer Bore, Thread, Neck, Neck Step, Bottle Height
• Autonomous and streamlined training and measuring techniques reducing operator error
• Audit trail of all user interaction, designed to strengthen Quality Management System
• Database logging of results for traceability back to machine, date and time
• Measurement accuracy down 0.015 mm
• Industrial grade vision and automation hardware
• Automated self-training for new product setup
• ISO9001:2015 Compliancy

Options include :
• Touchscreen
• Weight checker
• Colour Inspection
• Databasing of all image data

The Qdc Bench has been designed as a highly intuitive system, users can quickly and easily add new bottle recipes (bottle sizes and their measurement tolerances), calibrate and train the machine without the need for any engineering or external support.
Robotics:
ALS Mechatronic are a robotics integrator, with our preferred suppliers being ABB, Fanuc and Nachi but we are always willing to be guided by our customers’ preferences, working with other manufacturers such as Kawasaki.

We can provide a variety of innovative solutions from straight-forward rotary head trolley loaders, through to the additional use of vision technology to check part locations and part types for picking and assembly, as well as to accept and reject products during handling, stacking and loading processes.

Furthermore, we draw on the vast experience of our South African partner Directech to deliver turnkey robotic solutions for automotive, rail and mining sector customers, such as:

• Detonator manufacturing cells
• Welding cells
• Handling cells
• Adhesive applicator cells

As with all our machinery, health and safety conformity and regulatory guidelines is always at the forefront of what we do and as standard we include safety enclosures, standard operating procedures and emergency cut-offs, so you can be assured that your workforce remains safe.
Container Handling:
ALS Mechatronic manufacture a large and varied range of fully automatic, semi-automatic and manual bagging and debagging machines, state of the art conveying, palletizers, stackers and trolley loaders – suitable for a wide array of HDPE, PET and PP container types, styles and sizes.

All ALS machinery is built to globally recognised safety standards specifications using the latest technology from Rockwell Automation or Siemens depending on customer preference.

Key features and benefits across our range:
• HDPE, PET and PP containers management
• Small footprint compared to industry standard
• Can be fully flexible to run multiple products with simple changeovers
• Fully compliant with latest safety standards
• Built using modern parts, readily available worldwide
• Highly intuitive fault finding displays, down to sensor level
• Built in web-cams and remote control-system-access
• Options to suit all budget and requirements – from high speed production through to support for low outputs
Bagging & Debagging Machinery:
ALS Mechatronic manufacture a large and varied range of fully automatic, semi-automatic and manual bagging and debagging machines.

On the fully automatic bagger, containers enter an accumulation area and are collated into rows automatically. While this is happening, a bag is made to a pre-set length, cut and sealed and placed on a pair of clamp plates in front of the accumulation area. When a full pack of containers has been accumulated, it is transferred into the open bag and then the open end is closed, creating a hygienically sealed pack. The bag of containers is then ejected out of the machine and can be automatically stacked by an optional 2 or 3-position pallet stacker, Trolley Loader or diverted onto a roller conveyor for transportation to a central loading area.

The Belt Accumulation Debagger is a high-speed method of introducing bagged bottles into your conveyor system. The Mat-top Conveyor will continuously introduce bottles to the filler while the operator is removing another bag. The optional “hot knife” cut off is available to open bags even more rapidly and so further increase your productivity.

On a Semi-automatic Debagger full bags of bottles are loaded on to the end of the machine via a Mat-top Conveyor and the operator cuts the tail end off the bag. The bag is then pulled off the bottles through two rollers. The bottles are then released from the bag removal area and are driven by the Mat-top Conveyor toward the bottle accelerator. The accelerator sweeps off a single row of bottles at a time on to an exit conveyor and then on to the filler.
Stackers:
Whether the requirement is for straight forward 2 position pick and place or for a more sophisticated, robotic arm stacking system to enable greater flexibility and control; ALS can deliver the right solution to fit need and budget.

Stackers can add layer/slip sheets to each bag or just on certain levels depending on preference. These are often an important addition when packed containers are ultra-lightweight or when extra rigidity is required. A typical operating speed for a 3-position stacker is 3 bags per minute with no slip sheets and 1.5 bags per minute with slip sheets. Packs can be stacked to any height, up to 3 metres.

For easy transportation and/or storage, ALS have designed a novel, collapsible trolley system. We are happy to provide the full trolley design specifications free of charge to our customers, for production by their own local fabricators, who can invariably deliver this at the best possible price.
Palletisers:
The ALS fully and semi automatic Palletisers pack plastic containers onto half or full height pallets up to 1400mm square. The machine loads empty pallets after they have either been automatically loaded via pallet dispenser and optional feed roller conveyor into the hoist area or have been added manually by an operator.

A servo controlled hoist (capable of carrying up to 1,000KG in weight), then loads the pallet into position ready for the first layer of containers. The Palletizer then accumulates containers using a servo-driven pusher-arm and following bar so as to ensure bottles cannot fall over.

The 2 axis are linked together electronically for accurate control and travel at speeds of up to 2 metres per second, enabling high speed product accumulation and transfer onto the pallet.

Light Guard and Laser Safety Scanners create invisible entry barriers to ensure automatic and immediate machine cut off, keeping everyone safe.

Slip Sheets can be placed at each layer on the pallet by an operator or by the optional Automatic Slip Sheet Loader, which includes Top Frame loader as the final layer to complete the frame of the pallet.

Additional options that can be supplied include:

The ALS fully and semi automatic Palletisers pack plastic containers onto half or full height pallets up to 1400mm square. The machine loads empty pallets after they have either been automatically loaded via pallet dispenser and optional feed roller conveyor into the hoist area or have been added manually by an operator.

A servo controlled hoist (capable of carrying up to 1,000KG in weight), then loads the pallet into position ready for the first layer of containers. The Palletizer then accumulates containers using a servo-driven pusher-arm and following bar so as to ensure bottles cannot fall over.

The 2 axis are linked together electronically for accurate control and travel at speeds of up to 2 metres per second, enabling high speed product accumulation and transfer onto the pallet.

Light Guard and Laser Safety Scanners create invisible entry barriers to ensure automatic and immediate machine cut off, keeping everyone safe.

Slip Sheets can be placed at each layer on the pallet by an operator or by the optional Automatic Slip Sheet Loader, which includes Top Frame loader as the final layer to complete the frame of the pallet.

Additional options that can be supplied include:

• Complete roller conveyor to move full pallets out
• Strappers
• Wrappers
• Vision Inspection
Design Services:
Projects are underpinned by our experienced team of 3D mechanical design and electrical systems design engineers. For turnkey and the more complex assignments, we can produce automation animations to help you and your colleagues visualise your investment for added reassurance.

We take a multi-disciplinary approach to our design services to ensure seamless integration of your automation control and mechanical components. Our mechanical design process is 3D by default to ensure there are no hidden surprises for you (or us!) when it comes to build and installation.

At ALS Mechatronic, research and development is continuous as we strive to offer the latest technology for our clients’ automation needs. If there is a specialist piece of machinery you require; or existing machinery that requires additional or updated control systems; or perhaps, processes you need innovative ways to automate, our talented team can create new concepts and model them, before bringing them to life.

We work with a network of trusted technology suppliers including; Rockwell Automation, Siemens, Eplan, Autodesk, SMC Pneumatics and Flexlink, that we couple with our extensive design skills and project management capabilities to ensure each project we deliver, exceeds our customers’ expectations.
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