CASE STUDY | Reynolds Group
Reynolds Group Ltd is a NZ-owned and operated company, established in 1991. They provide comprehensive end-of-line solutions for manufacturing and are the go-to expert for coding and labelling, product handling, line automation, supply-chain traceability, product inspection, and integrity solutions. Reynolds offers bespoke, turn-key systems tailored to specific industry requirements across the country.
THE CHALLENGE
Reynolds Group were a victim of their own success—securing more projects than their internal design team could manage. This spike in demand highlighted a critical need for additional engineering expertise to maintain their high standards of service and innovation.
The Reynolds team had come across Caliber before, while both working on a project for Automac, so they felt confident that Caliber could help bolster their team and meet the increasing workload without compromising on quality or efficiency.
THE SOLUTION
Caliber responded to Reynolds Group’s call for assistance by deploying one of our highly skilled Caliber engineers to work onsite with the Reynolds engineering team at their Penrose office.
Our engineer’s broad experience, encompassing both solid design principles and practical workshop know-how, made him an ideal fit for the dynamic and hands-on environment at Reynolds. His involvement spanned the full project lifecycle, from initial concept development to the creation of technical documentation, ensuring a seamless process and contributing to the team’s success.
PROJECTS & TASKS
Automated Pallet Strap Labelling
Designed the full automated machine and the new end effector for the UR5 Cobot Robot. The end effector needed to be able to pick up a flat printed label and fold the label back on itself, over some pallet strapping. The end effector needed to be light enough to be fitted to the end of the UR5 which could only take a payload of 5kg. The robot had to be able to apply the label to the front face of the pallet and the side of the pallet. The project path for the UR5 was done using RoboDK and supplied to the Automation Team to get the waypoints. Involved in the full life cycle of the project.
Semi Automated Finished Board Labelling Machine
Took an exciting design that only had drawings from the 2000s and modelled the machine to be remanufactured. Brought the machine up to current health and safety standards. Added in the new features that had been sold with the machine, additional drive row, last row disengagement unit when running shorter boards. Supplied new assembly and manufacturing drawings for the updated machine. Did the technical documentation for the machine. Involved in the full life cycle of the project.
Test Sample Labelling
Added safety guarding to an existing machine to ensure it meets the Health and Safety standards while keeping the machine accessible. Helped to run and test the machine to ensure it meets the customer buyers specifications.
Automated Pallet Labelling
Updated the configuration of the labelling unit to be able to reach the desired labelling positions without having to use any new parts in the configuration. Got the projected path of the UR5 on RoboDK and supplied the path to the Automation Team the write the program for the machine.
“Gene is great to work with. He stays on task well, but without putting his blinkers on—he keeps on top of what else is going on in the department so he can operate accordingly. He's happy to get stuck in (has been helping out on the shop floor a fair bit) and has a great attitude overall. He's also communicated really well with the rest of the team.”