High-capacity finishing for premium UK automotive brands
In the tier-1 automotive supply chain, producing flawless finishes on highly visible plastic components is a strict requirement. For Rosti McKechnie Ltd, based in North Yorkshire, United Kingdom, the challenge was to establish a high-speed, flawless coating line for premium parts, including Jaguar engine covers. To achieve this, CALDAN engineered one of its largest installations: a sprawling 498-meter P&F140 power & free floor conveyor system, designed for unmatched throughput and process control.
The challenge: high-speed processing of premium automotive plastics
The Rosti McKechnie facility required a highly sophisticated material handling solution capable of managing a relentless production pace across a massive footprint. The system had to overcome several specific operational hurdles:
1. Exceptional scale and speed: The conveyor needed to span 498 meters while maintaining a rapid 1.0-minute variable cycle time, achieving an output of 60 wagons per hour.
2. Large component dimensions: The system had to transport tall automotive plastic components, with dimensions up to 1,250 x 400 x 2,100 mm and weights up to 75 kg per wagon (including jig fixtures).
3. Flexible operator interaction: Depending on the specific production batch, the loading and unloading zones required the flexibility to operate either in a stationary stop-position or in a continuous running mode.
4. Precision rotation: Parts needed mechanical rotation while the chain was continuously running to ensure even coating during the spray processes.
The solution: P&F140 power & free floor conveyor system
To meet these demanding high-volume requirements, CALDAN installed the P&F140 floor conveyor. This heavy-duty system is ideal for extensive, multi-stage automotive lines. Key technical features of this UK installation include:
– Dual-speed synchronization: The system is intelligently designed with variable speeds, utilizing 1.89 meters per minute through critical process areas for perfect paint application, and a rapid 6.0 meters per minute for transfer transportation between zones.
– Advanced turning capabilities: The 4-wheeled wagons are equipped with 90-degree lockable turning devices, allowing for precise mechanical rotation without halting the continuous flow of the chain.
– Versatile load and unload stations: The advanced power & free logic grants operators the ability to safely handle large components either at a complete standstill or while the line is moving, maximizing ergonomic safety and efficiency.
– Heavy-duty cardan chain: Driving the impressive 498-meter track is our signature cardan chain, providing the robust durability needed for a system of this immense scale.
Strategic impact on UK manufacturing
The Caldan UK conveyor installation at Rosti McKechnie is a testament to the scalability of our systems. By integrating the P&F140 technology, the North Yorkshire facility operates a highly dependable, high-capacity finishing line that consistently meets the rigorous quality standards of luxury automotive brands like Jaguar.
– Industry: Automotive plastics and components (UK)
– Application: Surface treatment of plastic parts (e.g., engine covers)
– System type: P&F140 power & free floor conveyor
Partner with the UK’s automotive conveyor experts
CALDAN delivers industrial-scale material handling solutions for the United Kingdom’s most demanding production environments. Our 498-meter installation at Rosti McKechnie proves that we can scale our P&F140 technology to meet any throughput requirement. Contact our UK team to discuss how we can optimize your high-volume finishing line.
