Automation and Innovation: CenFRA Leads the Way

CenFRA, Europe's first robotics and automation centre, was formally launched at its new premises in Doncaster on 22 May 2008. It has already received requests from more than 50 companies for technology audits hinting at the not-for-profit centre's future success and demonstrating the need for such an organisation in the food and beverage industry.

Driven by food industry professionals, CenFRA is committed to improving the competitiveness, profitability and sustainability of UK food and drink companies by introducing them to robotics and automation through technology audits, identifying opportunities and offering practical advice on equipment and its suitability.

The centre's mission, as confirmed by Michael Taylor, chairman of CenFRA, at the official opening ceremony, is "to support the long-term sustainability of the UK food and drink industry by providing independent affordable solutions." The centre's board is made up from food and drink industry professionals dedicated to providing help and solutions to the industry.

Frances Penwill-Cook caught up with CenFRA's centre manager Nigel Hall to find out more about what is behind the formation of the centre and what it is offering UK-based food and drink companies.

FPC: Who set up CenFRA and how was it funded?

NH: Yorkshire Forward have principally funded CenFRA but it has had additional support from Northern Way, an amalgamation of the three Northern-based development agencies. The centre is also in a partnership with a consortium lead by the University of Salford, who provides technical expertise from its leading independent robotic and automation facilities. I was actually part of the project team at the university when I was seconded to the centre.

FPC: Why is there a need for such a centre?

NH: Research carried out in the UK showed that it had the lowest uptake of robotics and automation in Europe. At the launch Mike Wilson, chairman of the British Automation and Robotics Association, spoke about how UK manufacturing is in decline and in his presentation revealed that per 10,000 production workers, the robot density in the UK is 44 compared with Germany at 171, France at 84 and Spain at 89.

The industry needs to gain knowledge about automation applications, the technology and the benefits. Yorkshire Forward identified two key areas: one, a lack of investment in this area; and two, a high level of activity of food and drink companies in the region. For example, in Grimsby there are 450 food companies including Copps, Headland Foods and Soya Magic. It was felt that if these and other companies across the UK could introduce robotics and automation, then the food and beverage industry would be more sustainable in the long term.

FPC: What does CenFRA offer food and drink companies in the UK?

NH: First and foremost, CenFRA is available either free of charge or for a small fee to food and drink companies outside of the catchment area. It aims to spread awareness for both robotics and automation as part of a service that includes: education and training, food automation technology audits, practical advice on automation equipment and its suitability to meet the specific requirements of individual business and research.

The research carried out, and advice given, is drawn from a number of highly respected sources such as leading engineers, technologists and academic centres and is in partnership with a consortium of the UK's leading robotic and automation facilities. Companies can receive free advice over the telephone or arrange a meeting at the centre in Doncaster where it is also possible to view appropriate, food–related robotic demonstrations.

CenFRA will work to alter the mistaken belief that robotics and automation are purely for the big players. The costs are not great and robotic solutions, which would ensure increased productivity and profitability, can be implemented now at a cost starting below £20,000, and are therefore accessible to both large and small businesses.

This type of investment figure would cover the basic robots and systems required for, say, a normal bakery employing, for example, 50 or more people. The centre aims to show companies how they can not just survive, but really thrive. The costs are not massive and the benefits are enormous.

FPC: Why should a company have an audit carried out?

NH: After an automation assessment of a company has been carried out by a site visit a detailed report is created. This shows the company where automation and robotics can be introduced, the costs involved and what systems can be used based on those that are currently available. It will show how the introduction of automation would increase both the company’s productivity and profitability.

This is clearly a no brainer for companies in the centre's catchment area, who are offered an audit free of charge, but for those located in other areas of the country it is still only a modest cost to have an audit undertaken.

FPC: Can you give an example of companies that have already benefited from CenFRA's input?

NH: Short films detailing some case studies of companies that have introduced automation are available on our website. The Blacksheep Brewery, based in North Yorkshire, for example, had some particular issues, including staff who were regularly suffering from repetitive strain injuries and back problems from lifting barrels and repeat work and, as a result, were having to take time off sick.

Automation changed the whole process: for example, closures on casks were removed automatically and processes for rebunging casks as well as filling them were also automated. Most of the work carried out by the staff is now overseeing rather than physical labour and has improved the health of the staff and made a big difference.

Askham Bryan Dairy College automated the milking of its cows and this has changed the working day completely. Not only does the farmer now not need to get up as early but the cows look after themselves rather than the farmer running around after them all day. The machine runs 24 hours a day and it's better for the cows as they come and go as they please. They are also 'comforted' by being lightly brushed on their backs while they are milked; it has been proven that the yield increases by as much as 20% as a result.

This all means that the farmer can go and do other jobs he often didn't have time for before and in the highly unlikely event there is a problem the system will automatically telephone a number that contacts the farmer or supervisor directly.’

FPC: What technology does the centre use and promote and why?

NH: The centre is an independent resource and offers impartial advice. However, it works closely alongside all the UK robotic and automation companies in order to spread the message to the food and drink sector.

The strategy is to remove the mystique and uncertainty in the use and investment in robotics, which has occurred in the past, due to a variety of misconceptions that include the views that they are too complicated and that specialist skills are required to programme robots, combined with a short-term approach taken to investment. The truth of the matter is that robotics offer opportunities for improved ROI, will improve on overheads, productivity and reduce the impact of workforce sickness and decreased productivity.

The companies we work with are all motivated towards boosting the competitiveness of UK companies through drastically reducing operating costs, improving production lines and employee satisfaction and increasing product manufacturing flexibility.

FPC: How has automation and robotics helped other industries?

NH: Car manufacturers, for example, have regularly implemented new technologies to improve their systems and their profitability. Jaguar uses robots to seal cars making sure all products are sealed to a consistently high standard. Overall production increases, but the costs do not, and now it's time for the food and drink industry to embrace robotics and automation and its rewards by taking advantage of the support that CenFRA can so readily and willingly offer.