European Conveyor Systems (ECS) has completed a contract for 34 custom-built work-benches, a powered conveyor, check-weigh scales, a vacuum-assisted lifting device and eight trolleys as part of a major investment to support research and development at GlaxoSmithKline
Like all pharmaceutical companies, GSK is required to carry out a series of clinical trials to test each potential new drug before it is approved for use. These can last up to 15 years and at any one time several hundred different formulations are being evaluated by GSK in this way. Because of the number involved, the need to ensure the integrity of the trials programmes and the importance of successful outcomes for the future of the company, GSK has invested in a purpose-built warehouse, in Harlow, Essex, specifically to handle the storage and delivery of drugs at the investigational stage of development.
Development strategy
At present about 4,000 shipments are sent from the warehouse each month to all parts of the world in response to orders from clinicians, and this figure is projected to increase as part of the company’s development strategy.
Because of the purpose for which the products are being used, all orders have to be picked, packed and despatched with complete accuracy as well as maximum efficiency, so the warehouse incorporates a number of special features and operates in accordance with strict procedures. Following a previous successful installation for GSK at Harlow, ECS was awarded the contract for the packing area.
The investigational drugs are delivered on pallets to the bulk storage section of the warehouse, from where they are taken in batches to a separate picking, packing and despatch area fitted with two high-volume vertical storage carousels. Orders are picked from the carousels and taken to work-benches where they are packed for shipment. A powered conveyor runs beside the packing benches and moves the sealed packages to the despatch area, which is operated by a third-party logistics provider. Weighing scales integrated into the despatch end of the conveyor allow operators to check the weight of each item. If it is less than 15kg, it is lifted manually on to a pallet or into a roll cage. If over 15kg, the vacuum lift unit is used.
The conveyor feeding into the despatch area and on to the weigh scale has a zero-pressure accumulation feature, which allows boxes to queue without touching and be indexed forward one at a time for check-weighing. The structural frames consist of rigid deep aluminium profiles with smooth snag-free surfaces, and the use of high-quality drives has produced noise levels below 68dBA as well as reducing energy usage. A power-save mode has also been included, which switches off the powered sections of the conveyor when they are not in use, which also lengthens component life.
The conveyor is controlled by an industry-standard PLC unit that provides completely automatic operation and has sufficient capacity to allow for future extensions. All commands transmitted are stored in the system memory in the event of a shut-down, so the conveyor re-starts from the same position as before the interruption. Text displays on the control cabinet identify individual motor malfunctions and emergency-stop activations.
Comfort and convenience
The design and operation of the warehouse have given a high priority to the comfort and convenience of the staff, as exemplified by the check-weigh facility, the vacuum-assisted lift mechanism and also the design of the work-benches and trolleys which are adjustable from 850mm to 1,050mm to suit the warehouse staff.
