A prototype potato grader may have kicked off RJ Herbert Engineering back in 1971, but the family-run business has successfully diversified its manufacturing service to meet changing demand for custom-built equipment.
The company recently committed itself to developing more sophisticated automated systems, such as vision machines and robot end-of-line packaging, meaning it now provides a more complete range, instead of only providing machinery to the pre-packing sectors. This transition in technology from mechanical to electronic has required a strong management strategy and excellent high-tech personnel to support these advances, both of which Herbert is proud to be able to supply.
With an annual turnover of £10 million, the company employs 130 people in design, engineering, manufacturing, installation, sales and marketing functions for the UK, and also more than 15 export markets.
A wide range of equipment was on display to growers and packers at Herbert’s bi-annual open days in March 2005. Visitors were taken on a tour of the facilities, including the expanding engineering and design teams, which work closely with customers, to develop new machinery concepts, and during the pre-build stage.
General sales manager Andy Hubble says this relationship continues throughout the installation stage: “Our staff work conscientiously on the customer’s site, conduct full risk assessments and schedule activity to take into account the client’s time frames to ensure a successful and efficient install.
“It is in our best interests that our clients are fully satisfied as it is a major capital investment for them - we encourage them to come back to us for further education and training.”
The spacious, clean and well laid out assembly areas cover an area of 7,500 sqm which comprises two fabrication areas, two large assembly shops, and a high level production office which monitors the processes. Marketing manager, Jo Herbert, points out this facility is important primarily because most of the company’s product range is custom-built.
She says: “Costs of every job are monitored throughout the eight to 10 week assembly line. The projects we undertake are very big and it is important to monitor the project time and costs to calculate revenues.”
Output demands, maintenance issues and ease of operation have been hot topics throughout the Herbert product range where many improvements to existing systems have taken place. This is due to recent industry pressure coming from retailers requiring packers to improve and upgrade grading quality and packaging, while keeping costs down. “This has made producers and packers invest in labour-saving and increasingly efficient handling equipment,” says Hubble. “This includes improvements to the ease of machine maintenance because downtime is costly.”
The company’s core activity remains in the fresh potato packing sector but it has had to address the fact that, over the last five years, its fresh produce customer base had declined by 30 per cent, and it cannot be totally reliant and exposed to one sector.
“Throughout 2004, management reviewed the group’s operations and conducted an analysis of resources which needed to be addressed. We looked at all areas across the business sectors and have begun to fill in those gaps this year with the aim being continuity of service,” explains Hubble.
A new type of electronic grading will be on display at this year Potato Emmerloord Exhibition which compliments the company’s existing Upgrader. The new Autosort was launched last year following significant research and development and has resulted in a vision machine at a higher level. The new machine includes improved software, simpler operation, increased reliability and efficiency, requiring less maintenance - all resulting from working very closely with customers and listening to their needs.
“We also realise that it is important to offer customers with existing machinery the opportunity to upgrade - we will refurbish old equipment, whether it is a single piece or a complete line, and where possible update the specifications to incorporate the latest technologies. This is less costly, at approximately 60-65 per cent of the cost of a brand new line,” he says.
However it is the changes in the market that have presented the company with new opportunities to manufacture specialist machinery, and it is in this sector RJ Herbert has been focusing its business. A major part of the business is now refining and developing new machinery to existing industries rather than developing new products to new markets.
Hubble says: “There has been an increase in demand for mobile systems, that operate in the field, directly linked to the harvesting process. This demand was met with a positive response from our design and technical support teams who are an essential factor in maintaining a firm foothold in this market.
“In the same way, end of line automation has developed from simple singular robot installations to fully integrated systems that include robots and automated tray handling. Machine automation provides considerably simplified handling systems,” he adds. “This has resulted in better efficiencies, reduced labour and less health and safety issues for our customers.”
Changes to health and safety legislation have also affected the sector, for example the introduction of maximum bag weights and lifting heights. “This means palletising equipment is becoming more important and Herbert has introduced equipment which can be programmed to pack potato bags onto pallets - we see demand for this type of product increasing throughout Europe,” says Hubble.
“We have been at the forefront of machine evolution by adopting new technology in our product range. We were one of the first to include image analysis in systems for produce grading,” he adds.
Herbert’s autosort electronic potato grader uses high-speed colour cameras placed above the grading line which take a series of images of each tuber as it mechanically rolls through. These pictures are transmitted to a computer that compares each potato’s particulars to a programmed benchmark-grading standard; in turn the tubers are automatically graded by defect and size selection. Herbert says: “Optical grading is a great labour-saving device that improves speed, time and space as it allows higher throughput.”
The importance of improvements to potato washing has also grown and the company met this demand in 2004 with the introduction of a stainless steel barrel brush washer, designed in New Zealand. The Vege-Polisher barrel brush washer is suitable for all types of potatoes and removes skin surface defects. Hubble explains that trials have proved that up to three per cent of produce is improved in classification from rejected to packable grades.
“The specialty brush washer has multiple rotation brushes and can be altered to use different brush technology, and brightens skin finish. A new generation of the Vege-Polisher is launching this year - five units have been sold to be installed this autumn,” he adds.
The company has also been working on collaborative projects and setting up partnerships with companies with innovative ideas; “We see no need to re-invent equipment that already exists and compliment our own products and we are always looking for new concepts globally.”
However for the fresh pack industry buying sophisticated equipment involves considerable capital investment and although Herbert try to maintain low costs, the steep rise in steel prices (up to 30 per cent in 2004) impacted machinery production costs (the company’s average production costs increased by almost 4.5 per cent over the year). “Luckily this coincided with an internal review of stores handling,” says Hubble, “which has resulted in halving the average holding time of components and materials; the resultant savings have gone to offset some of the increased steel costs.”
In addition product support and maintenance have become very important issues and Herbert Engineering is well aware this is a highly significant factor in their marketing strategy.
The most important commitment to Herbert’s European customers has been the new sales office and service base opened in Eindhoven, in the Netherlands during 2004. Managing director Mark Verschuren says: “It has been a very busy year supporting and working with existing customers. We are now well equipped to cope with new enquiries and supply our technologies to customers in Europe. This daughter company provides the group with greater operating flexibility and a shorter response time for servicing.”
Hubble summarises the company’s philosophy: “We have a total commitment to quality in construction, components and after sales service to ensure our customers are provided with reliable, robust systems that are gentle to their valuable crops. These new concepts have enabled Herbert Engineering to maintain its position at the forefront of the UK industry and to expand to the forefront of the industry in Europe and worldwide.”
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