—SOLUTION

Boomf benefit from 600% growth with ABB robot

An ABB robot has been installed by systemintegrator Newtech at a company thatspecialises in the production ofpersonalised marshmallow confectionery.

Started in 2013 by founders JamesMiddleton and Andy Bell, Boomf enablesits customers to print their choice ofphotos, graphics and messages on tomarshmallows which can then be sent to achosen recipient as a quirky alternative toflowers, chocolates or greeting cards.

The idea proved so popular that within a year thecompany’s manual production line at its factory inReading began to struggle to keep up with orders. Muchof the delay was happening at the cutting stage. Theexpectation of high quality meant that each productneeded to be carefully cut, causing a bottleneck in theproduction flow. Difficulties in achieving a consistent highquality cut also meant that a lot of product was beingwasted.

With the company specialising in such a niche product,the founders feared that solving this problem withautomation would require custom-built equipment andmachinery. In the words of James Middleton, “There wasno marshmallow printing shop around the corner.”

James used his physical manufacturing background tobegin researching solutions online. Looking at variouscutting machines for the food industry on YouTube, hecame across a video of a robot cutting application whichused an ABB six axis robot and an ultrasonic blade to cutcakes. The automated system was integrated byNewtech, an ABB Robotics UK Authorised Value Provider.

Located in Sharnbrook, North Bedfordshire, Newtechspecialises in automation for the food industry and wasthe first company in the world to create a commercialrobotic cutting solution combining a robot arm with anultrasonic blade.

Newtech and then we went up to trial some

solutions,” enthused James.perspel estior aliamus et ea coribea turibus sita ip-samet lant apit voloreic tore pratem dissim faccus-apelis volo totatus as aut doluptatis et atur? Atem-qui rerferrore parunt is mosam, explit eaquia volupti quossuntur apient, corectemosam vitature pre est, cuptatiur aut expel in nihil es atur, te velites tibeatquo est et pra si aut estium explit eaquia vo-lupti quossuntur apient, corectemosam vitature pre est, cuptatiur explit eaquia volupti quossuntur. Volo-ris aut vent, simusam quam am faccum.

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“As soon as I saw the video, I thought that’s thesolution we need. We got on the phone, contactedNewtech and then we went up to trial some

solutions,” enthused James.

Like any robot installation, trials are required toensure the best results. Because the originalmachines were set up to cut cakes or cheese, theyweren’t suitable to cut marshmallow which is aninherently sticky product. Through applying amechanically PTFE-coated blade to the ABB IRB 1200,Newtech were able to come up with a solution. Theblade passes through an oil reservoir before the cutis made in order to ensure a suitable surface forcutting. Once the marshmallow is portioned, theblade passes through a cleaning tank beforerepeating the process.

A clean-cut design is of the utmost importance toBoomf. James Middleton explained, “We make surewe have a precise square, not just somethingthat’s almost a square, and we have very sharp anglesand edges so that we have a good printingsubstrate.”

When the process was performed manually, Boomfemployed ten people to cut the trays of marshmallow

into 40mm by 40mm squares.

Now that the process has been automated, theprocedure takes 17 seconds. Newtech alsointegrated intelligent vision software into therobot cell to ensure that Boomf would get theperfect cut each time. According to JamesMiddleton, “There’s next to no wastage now andthat’s been a real benefit to the figures.”

—ABB robot providing

consistent high

quality precision

cutting of

marshmallows

After every five or six cuts, the blade would need to becleaned. In total this took five minutes. Due tomiscuts, there was also a lot of wasted product. Nowthat the process has been automated, the proceduretakes 17 seconds. Newtech also integrated intelligentvision software into the robot cell to ensure thatBoomf would get the perfect cut each time. Accordingto James Middleton, “There’s next to no wastage nowand that’s been a real benefit to the figures.”

Jaz Gill, Sales Manager at Newtech explained how theAVP uses vision technology in this and many otherprocesses to accurately cut and track products as theycome into the robot cell. “The vision technology scansimages and then uses 2D vision from the top of thecell to recognise the product. The data is then sentinto the robot to follow it – be it a tart, cheesecake or asandwich, the camera ignores any other elements toachieve a perfect and accurate cut.”

In addition to improved product quality, the robotsolution has raised productivity levels significantly.Now Boomf have the flexibility to respond to changesin demand.

The confectionery company receive a large increase inorders during holiday periods such as Christmas andValentine’s Day and need the resources in place to copewith fluctuations. Improving the process has also enabledBoomf to focus on other areas of the business such asexpanding delivery to more countries and looking at howother processes could be automated.

Jaz Gill informed us, “We develop a partnership with ourcustomers and look at where we can add value across thewhole of their production line. In Boomf’s case, we cancut the product perfectly, but they still have a challenge inmanually putting the product into boxes.” Over thecoming months, Newtech will begin trialling various usinganother ABB robot.

Further, using an IRB 1200 within a machine cellallowed Boomf to improve the health and safety at thesite. James Middleton was a victim of the manualprocess before the automated system was installed.He severed a nerve in the end of his finger whilstcutting a batch with a knife. Removing the humaninteraction from the cutting process removes the riskof such accidents and the employees can apply theirskills to other areas of the business such as operatingthe robot.

Overall, Newtech’s automated solution has been a realsuccess for the company. Ease of use is ensuredthrough the use of a HMI which enables staff tooperate the cell following simple training. Jay Gillinsists this means companies “won’t have to worryabout having an engineer on site.”

In terms of finances, Boomf were well aware that as astart up there would be a lot of cost. However,through investing in a robot the company has alreadyexperienced the benefits, and in their second year ofbusiness have grown at an astounding rate of 600%.James Middleton added, “It’s the benefits of havingthe robot that’s allowed us to grow that much in oneyear.”

Jaz Gill firmly believes that robotics and automation ingeneral is completely underutilised within food andbeverage. “It’s a whole culture change that we need tobring to our customers and their partners, for peopleto understand that the use of robotics, the use ofautomation, the intelligence, is not only far moreeconomic than it’ ever been and yields a fasterpayback, it’s incredibly easy to use,” he concluded.

When asked about what he would say to UKmanufacturers who were thinking of investing inrobotic automation, entrepreneur James Middletonwas encouraging. “I’d say go for it. The success thatwe’ve had with our robot speaks for itself. Anyinvestment in robotics is a great decision for anycompany that wants to insure their future in anincreasingly digital market.”

abb.com/robotics

—ABB Ltd.Milton KeynesUnited KingdomTel: +44 (0) 1908 350300

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