INDUSTRY

At Modular Conveyors Ltd (MCL), we specialise in the design and manufacture of conveyors and components for the materials handling industry, system integrators, OEMs, automation businesses and their clients. A proud leader in our field, one of our key hallmarks is delivering cutting-edge designs through a partnered approach with all vested parties — ensuring the best outcomes possible and ongoing R.O.I.

In 2022, we had the privilege of collaborating with T&G Global, a household name in New Zealand and one of the nation’s most iconic produce growers and apple exporters. The system featured various conveyors, and specialist devices — capped off with integrated robotic palletisers for unmatched efficiency.  This case study demonstrates how we engaged with and interpreted the system integrator and end-user client needs successfully.   

T&G Global needed a comprehensive conveyor system for their food processing plant to improve the movement of produce from grading to packaging. The system needed to plug and play with third-party food grading equipment, carton erectors and robotic palletisers. Time was of the essence, and their initial provider couldn't meet the project's tight deadline.
Faced with this pressing need, T&G Global turned to MCL for our expertise and proven ability to turnaround complex projects. Noting that we were already juggling multiple ongoing projects, we were tasked with designing a system that not only met their immediate needs but was also replicable for future use within the next 12 to 24 months.

MCL rose to the occasion by delivering a fully customisable and innovative conveyor system tailored to T&G Global's idiosyncrasies—no clearer testament to our ability to prioritise efficiency without ever compromising on quality.

Our engineering team carried out a thorough analysis of T&G Global's operational requirements. Recognising the need for a system that could handle large volumes while maintaining gentle handling of produce, we crafted a modular conveyor system featuring:

• Transport Conveyors: Over 154.5 metres of Belt Driven Roller (BDR) conveyors were installed to enable efficient and reliable movement of goods across their facility.
• Infeeds and flat belt conveyors: 43 custom-designed infeeds and flat belt conveyors were added to facilitate smooth transitions between different stages of the processing line.
• Advanced motor technology: The inclusion of 24vDC driven rollers provided energy efficiency and precise control, essential for handling easily bruised produce.
• Zinc-plated rollers and pneumatic lift units: These features boosted the durability and flexibility of the system, making adjustments and maintenance much simpler.
• EZQube control cards: State-of-the-art control systems were integrated to provide real-time monitoring and control, creating a conveyor system with better performance overall.
• Integration with third-party systems: The conveyors were designed to work collaboratively with existing food grading equipment, carton erectors, and robotic palletisers, creating operational cohesion.

By honing in on modular design principles, the system allows for easy replication and scalability, allowing T&G Global to roll-out similar conveyor solutions in other facilities within 12 to 24 months.

MCL's innovative conveyor construction not only met but exceeded T&G Global's expectations. The new system markedly improved throughput slashed manual labour costs and improved the way they utilised space within their existing facility. By adding advanced features like 24vDC driven rollers and EZQube control systems, T&G Global made sure their operations kept pace with their ambitions. 

The project's resounding success has positioned T&G Global to replicate the conveyor system in other locations, producing consistent performance across their facilities. Our collaborative approach and solution-focused mindset earned us positive feedback from T&G Global and our project partners, Blue Fruit Design and Optimal Tech.

"Working with MCL was a breath of fresh air. When our original construction project plans hit a snag due to time constraints, MCL didn't just step in—they took the time to really understand what we needed. It felt like partnering with a team that genuinely cared about our success. We're looking forward to collaborating with them on future projects."

 — Blue Fruit Design

At MCL, we firmly believe that every challenge is an opportunity to innovate. Our successful partnerships with numerous System Integrators for various Global Brands speaks to our commitment of delivering customised conveyor solutions that meet exacting specifications. No job is too big or too small for us—from a single roller to a fully automated system, we are here to help.

If your business is seeking advanced conveyor solutions that integrate effortlessly with existing systems, we invite you to contact us. With our local expertise and global reach, MCL is your trusted partner.