Sheridan Automation Tote Range

The Brief

IPL is a leading packaging manufacturer, partnering with customers to deliver sustainable solutions to the food, consumer, agricultural, logistics and environmental end-markets.

Their business is organized into two areas: Consumer Packaging Solutions (CPS), and Environmental, Returnable, industrial Solutions (ERIS). As part of their strategic growth plan, we were tasked with researching the warehousing and automation market and designing a new durable automation tote range. The new tote range would be produced in various sizes and must interact with the latest belt and roller conveying, automated handling, warehouse racking and OSR (Open Shuttle Robot) technology.

The Process

Through our initial research and early Concept Generation work we identified that a flat base was key to efficient conveying, however a single wall flat base would be weak, be prone to distortion and have a limited weight capacity. Our concept was based around a four-side cored twin wall base, combined with a large central change part enabling the customer to specify either full flat internal, full flat external or a heavy duty 50kg hybrid base option. In addition to this we designed the totes so that one tool could produce different height products with common features. Throughout our development and prototyping process, we liaised with leading automation equipment manufacturers, system integrators and facilities insurance regulators to ensure the new range was both compatible and compliant.

The Result

The design flexibility and tooling modularity achieved through our design enables IPL to offer a truly tailored tote solution to their customers. Ensuring that the tote is fit for customers specific application, whilst seamlessly integrating with their existing or planned automation assets. As a result, IPL’s Sheridan range has been disruptive to the UK automation industry and has won several large retail tote tenders.