Automated Welding Transforms UK Food Container Manufacturing
Client Profile
In March 2023, a UK-based food processing equipment manufacturer specializing in hygienic containment systems sought to modernize their production of cylindrical vessels with dome closures. Facing increasing demand from the dairy and pharmaceutical sectors, their reliance on manual aluminum welding processes had become unsustainable.
Production Challenges
- Extended cycle times: Each vessel required 16-18 hours of manual welding
- Material difficulties: 5xxx-series aluminum alloys demanded specialized welding expertise
- Quality inconsistencies: Visual and penetrant testing revealed porosity and lack of fusion defects
- Labor constraints: Certified aluminum welders commanded premium wages in the UK market
Technical Complexities
- Access limitations for manual welders at certain angles
- Heat dissipation variations across different material thicknesses
- Hygienic surface requirements prohibiting excessive grinding
Automation Solution Implemented
- Industrial robotic arm with extended reach for large-diameter vessels
- Specialized aluminum welding power source with pulsed capability
- Dual-axis positioner enabling optimal joint presentation
- Laser seam tracking to accommodate part tolerances
Operational Transformation
- Cycle time reduction: From two days to six hours per vessel
- Quality improvement: First-pass acceptance rate increased from 65% to 96%
- Labor efficiency: One technician now oversees multiple robotic workstations
Implementation Process
1. Process Development
- Conducted weld procedure qualification tests
- Established parameter sets for various joint configurations
2. System Integration
- Designed custom tooling for quick vessel changeovers
- Implemented purge gas systems for critical welds
3. Personnel Training
- Upskilled existing staff in robotic operations
- Developed standardized work instructions
Client Benefits
- Enhanced competitiveness: Ability to quote shorter lead times
- Improved working conditions: Elimination of strenuous overhead welding
- Quality documentation: Automated records for each welded vessel
Industry Significance
- Solves specialized material joining challenges
- Addresses skilled labor shortages
- Elevates quality in regulated industries
Sustainable Outcomes
- 30% reduction in shielding gas consumption
- 60% decrease in post-weld rework
- Improved energy efficiency per welded unit
About Aixsen
At Aixsen, we deliver end-to-end industrial automation systems designed for demanding manufacturing environments.
We deliver precision laser cutting, robotic arc welding, and intelligent material handling solutions—designed as standalone systems or integrated lines, fully engineered around your specific process, quality requirements, and output targets.
