bespoke conveyor 3D design

Increasing Hand Packing Output For Fullwell Mill

Recently our team at UPM Conveyors were consulted to design a system to increase hand packing output to 150+ bars per minute for Fullwell Mill, based in Sunderland.

The experienced food manufacturer of specialty bars had developed Just 5, a range of Fairtrade and organic snack bars to complement their established Tropical Wholefoods brand. It became obvious that packing capacity needed to expand to accommodate the company’s new private label and existing contract bar manufacturing success, and we were able to create an effective solution.

Discover our process below and contact our team if you require any of our conveyor manufacturing services for the food and packing industry.

Our bespoke conveyor solution

Our experts liaised with Fullwell Mill personnel to establish the required production parameters and submitted 3D images which could be infinitely adjusted to suit on site criteria. These criteria included product flow, available floor area and operator preferences on best working practice.

The end result was based on an in-feed conveyor having catered for X-ray:

  • Metal detection
  • Check weighing to transfer product to a carousel
  • A carousel where operators could comfortably sit to collate and pack bars
  • Weight range of 20g to 1kg including quad (stabiles; gusset and pillow packets)
  • Product put into outer boxes
  • Outer boxes easily transferred to transit boxes on an overhead conveyor
  • Overhead conveyor can be reversed in direction if required

UPM Conveyors also incorporated variable speed control on each conveyor with strategically placed emergency stops and ensured the total system was modular in construction to allow for future expansion. This was important due to the ongoing success and growth of Fullwell Mill.

Enquire today

If your business requires effective conveyor solutions, get in touch with our team for an initial discussion about your requirements. Please call 01753 548801 or email

All of our conveyors are tested to UK standards and all health and safety CE requirements, whilst our in-house project management team makes the process of design, installation and commissioning run efficiently.

Posted in Case Studies, News.