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The Pro-Load live bird handling system features a steel transport frame (module) which carries plastic drawers to contain the birds

Live-Bird-handling-Assembly-render Wrightfield

Pro Load Overview & Specification

The Pro-Load live bird handling system is based around a standard galvanised steel transport frame (module) which carries plastic drawers to contain the birds. Modules are manufactured in either 3, 4 or 5 tier variations dependent on birds to be handled.

The modules are either hand or machine loaded on the farms and transported to the processing plant on the back of trucks. The modules are then unloaded onto the Pro-Load system, which is an automated system for unloading the drawers from the modules and presenting each drawer to the hang-on operators. Each drawer and module is washed, drawers are loaded back into the modules and each filled module then loaded back onto the truck.

The Pro-Load system accommodates 3, 4 or 5 tier modules. Modules are constructed from Galvanised Mild Steel and weigh approximately 650lbs per unit.

Pro Load Live Bird Handling System with multiple configuration options.

Module In Feed

  • Designed for more efficient cleaning and easier maintenance

Drawer Turn Unit

  • Guarantees that drawers are pushed at their strongest point

Hang On Personnel Stand & Conveyor

  • Providing a safe and optimal position working area

Drawer Re-loader

  • Automatically accumulates the drawers and reloads them

Control System

  • Providing optimum efficiency and speed for the system

Module Wash & Water Filtration

  • Removes debris down to 1mm, minimal overspray and water loss

Drawer Accumulation

  • Tailored to the speed requirements of the live bird system

Drawer Inverter

  • Inverts the drawers into a base up orientation or vice versa

Module De-Stacker& Re-stacker

  • Reduces the number of forklift movements
pro-load-3 Wrightfield

Contact Us About Pro Load

Consent

General Design Specifications

  • Module in-feed
  • Module shuttle (Low capacity)
  • Module shuttle (High capacity)
  • Module Wash
  • Water Filtration System
  • Module Takeaway Conveyor and Roller Outfeed
  • Infeed / Outfeed Buffers
  • Draw Push Out Tower
  • Drawer Transfer Conveyor
  • Drawer Turn Unit
  • Drawer Accumulation
  • Hang on Conveyor, Hang-on Personnel Stand
  • Drawer inverter
  • Drawer Washer Infeed
  • High Level Drawer Wash
  • Control

Pro Load Extras

  • Module De Stacker & Re Stacker
  • Drawer Dip Tank
  • Drawer Re Loader
pro-load-5 Wrightfield

The following brochures and data sheets are available as PDF downloads. If you would like a printed version please contact us and request

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Food Equipment Maintenance

Wrightfield offer a professional and responsive after sales service. Including both spares & various service options we can help keep your business up and running.

As partners of both Intralox (for the full range of belts) and SEW for motors, along with our ability to source from a range of manufacturers, as well as being able to manufacture or fabricate a variety of bespoke parts we are confident we can meet your needs, so why not give us a try when you next need replacement parts

We can provide planned maintenance on a scheduled basis, and well a providing skilled engineers for shift cover in the event of busy periods or holidays.

Our fully equipped vans are on call in the event of a breakdown.

Our After Sales service offerings can be bespoked to your particular requirements including:

  • Mechanical
  • Electrical (17th edition qualified)
  • Control systems
  • Belts, Motors & wide range of other purchased parts
  • Manufacturing, Welding & Fabrication available in-house
  • Breakdown Support
  • Service Contracts
  • Shift Cover
  • Planned Preventative Maintenance
  • Audits & Assessments
  • Remote Diagnostics
servicing and spares Wrightfield

Food Equipment Spare Parts

Belt Conveyor Components

We supply Conveyor Belting of all types including Food Grade Conveyor Belting, Grip-top Belting, PVC Conveyor Belting, Smooth. Belt Conveyor Components are available for all types of Belt Conveyors and include Drive Drums, Idler Rollers, Crowned Rollers and Motors.

  • Conveyor Belting – Smooth and Grip-face belts are available to suit a variety of applications. These are available in a variety of different colours.
  • Roller Drums – Drums are available to suit Wrightfield conveyors and other suppliers of belt conveyors
  • Bearings – We have a range of replacement belt conveyor bearings available from stock.
  • Sprockets and Drive chain – we have a range of replacement sprockets and drive chains available from stock. Non stock items can be obtained
  • Knock our Rollers – We have a variety of replacement knock out rollers available. Over the years we have manufactured rollers to suit conveyors that have been manufactured but the original manufacturer is no longer able to support / supply
  • Adjustable feet – We have a range of steel, plastic, steel, light and heavy duty adjustable feet available. We also manufacture bespoke feet that allow the height of a conveyor system to be raised ( which can provide a very cost effective way of adapting an existing conveyor system
  • Stainless Steel Ball Units – We are able to offer stainless steel ball units.
  • Geared Motor Units – We stock SEW geared motor drives for all of our conveyors, including lineshaft conveyors, belt conveyors,pallet conveyors,belt under roller conveyors and our flexible conveyors.
  • Intralox – we stock a range of Intralox components

In the fast paced world of food processing, unplanned downtime owing to broken machinery can have serious consequences. We understand this and provide conveyor belt parts to help companies get back up and running as soon as possible. Because of the complete set of services we offer we are also able to provide custom built components. We discuss these topics in greater detail below.

The advantage of plastic Modular-Belts 2

Conveyor Belt Parts – Custom Made Components

The fact that we own our own factory is an important factor in facilitating us to provide the efficient service we do. With no middle man to deal we are able to work directly with clients enabling us to save both time and effort. Moreover, we are in a position to fully understand the requirements of a client. Finally, with our own manufacturing facility, we are able to realise a client’s objectives and to provide them with custom made conveyor belt parts if required.

Conveyor Belt Parts – Aftercare Service

We provide a comprehensive aftercare service, as part of which we supply spare conveyor belt parts and components. Additionally, the service also includes planned maintenance so as to proactively avoid any potential issues that may occur to machines, as well as offering emergency breakdown repair.

elevators de elevators wrightfield

The following articles may be of interest when considering food equipment selection or operating requirements

Frequently Asked Questions on Modular Belt Conveyor Systems

1. Can modular belt conveyors be run on an incline? This depend on your product but usually up to 45 degrees can be achieved without flights…

conveyor system types specifications & selection

Conveyor Systems are mechanical devices or assemblies that transport materials, components, products or food with minimal effort.

Whilst there are a numerous different kinds of conveyor systems, they usually follow a standard configuration.

The advantage of plastic Modular-Belts 2

Plastic modular belts are perfectly suited to going round bends and curves

They can be easily repaired ( in the event of a breakage) and extended should the need occur. This has the advantage that the plastic belts can be changed quickly.

Frequently Asked Questions on Modular Belt Conveyor Systems

1. Can modular belt conveyors be run on an incline? This depend on your product but usually up to 45 degrees can be achieved without flights…

Frequently Asked Questions on Modular Belt Conveyor Systems

1. Can modular belt conveyors be run on an incline? This depend on your product but usually up to 45 degrees can be achieved without flights…

Frequently Asked Questions on Modular Belt Conveyor Systems

1. Can modular belt conveyors be run on an incline? This depend on your product but usually up to 45 degrees can be achieved without flights…

Meat

Fruit

Poultry

Veg

Seafood

Containers

Live Bird

Pet Food

Bakery

Ready Meals

MODULE CIRCUIT

Module in-feed

  • Stainless steel pressed sided conveyor, fitted with heavy duty modular section plastic chain, plastic chain section has been used as it has shown to have superior wear properties and allows for more efficient cleaning and easier maintenance.
  • The conveyor will be fitted with a hopper section at the loading point to aid the positioning of the module and to minimise the chance of possible damage, hydraulic scissor lift and single hydraulic drive.
  • Guarding will consist of a perimeter steel mesh fence attached to the main conveyor body and will incorporate quick action emergency stop buttons and or cords.
  • The hydraulic scissor lift is designed to be low maintenance but easy to work on for all essential works and routine greasing etc. the lift is fitted with a fast action safety curtain around its perimeter and non-return valves to support the lift in the event of pressure failure.

Module shuttle; (low capacity)

    • Stainless steel pressed sided conveyor uses dual plastic chains to transfer the module from the system infeed of the system across to the infeed of the module washer.
    • The chain used is common to the rest of the module circuit to keep spares inventory and costs to a minimum.

Module shuttle; (high capacity)

  • The general construction is the same as the above unit however for systems processing upwards of 50 modules per hour the modules are shuttled across using a transfer chain, this can either be powered by hydraulic or electric motors depending the customer preferences.

Module wash

  • The module wash enclosure and frame is completely constructed from stainless steel, and will contain a reciprocating conveyor section, this will allow for multiple passes of the module through the jet banks (this can be either pre-programmed or time dependant).
  • The conveyor will use plastic chain to allow for easy care and maintenance, it will be complete with its own hydraulic drive unit.
  • The module washer frame will incorporate 3 sets of stainless steel jet banks; each bank specifically designed and positioned to sweep debris from
    the module frame, all the banks will be installed using a quick release system to allow for quick effective cleaning away from the washer.
  • The module washer base will be fitted with a drain door for easy wash down and all the connections the module washer system. Pneumatically controlled doors will be fitted at the infeed and the outfeed to minimise overspray and water loss.

Water Filtration system

  • The module wash is connected to a water re-circulation system, capable of removing debris down to 1mm in diameter.
  • Filtration will be in the form of a rotary screen, complete with header tank and adjustable weir.
  • Filtered water will accumulate in a reservoir mounted under the screen where a series of pumps will deliver it through to the jet banks via stainless steel pipework, a recirculation pump will remove debris laden water from the base of the washer, and the water will then be pumped through UPVC pipework to the screen header tank.
  • Please note that pump size will be determined by the throughput required by the system.
  • The rotary screen will be driven by a shaft mounted motor so there will be no need for chains or adjustments, the screen will be self-cleaning using a back purge system that can either be pre-programmed to work at a fixed time or can be done manually to fit in with breaks etc.

Module Takeaway conveyor and roller outfeed

  • Stainless steel pressed sided conveyor, fitted with heavy duty modular section plastic chain, plastic chain section has been used as it has shown to have superior wear properties and allows for more efficient cleaning and easier maintenance.
  • This section again has its own dedicated hydraulic drive, this section is where the drawers are either manually reloaded or there is the option of an automatic drawer re-loader, this additional unit will stack the drawers into either 3, 4 or 5 high and then reload them into the cleaned module.
  • The reloaded modules are then fed out onto a roller section where they can be retrieved with the fork lift.

Infeed/outfeed buffers

  • To reduce the potential damage that a forklift could cause while loading and unloading modules from the system a heavy duty buffer section is used.
  • These frames will protect the system from potential abuse and accidental damage, these structure are securely fixed to the concrete by using a core cutter and sinking steel anchor points for the buffers to be bolted to, this allows for removal but does not compromise the protection it provides.
  • Buffers are constructed from mild steel and galvanised for long lasting protection.
  • The buffers will be tailored to suit the type of vehicle used whether it be a Moffatt or standard forklift.

Drawer push out tower

  • The drawer push out tower consists of a stainless steel frame, this is anchored to the floor and also the module lift frame to guarantee that the unit is secure and constantly pushes the drawers out square to the module.
  • The tower uses a hydraulic cylinder which drives the push out forks through the module, pushing the drawers through and out on to the drawer transfer conveyor.
  • The push out tower has been engineered for constant reliable service, but has also been designed for easy maintenance and features many unique design elements for easy servicing and reliable operation.

Drawer Transfer Conveyor

  • The transfer conveyors use twin uni-flex side flexing plastic chain, it is used due to its strength, durability and reliability, it has excellent wear characteristics and is virtually maintenance free.
  • The main conveyor frame and support legs are constructed from galvanised mild steel.
  • All the lids on the transfer conveyors are fixed from the top to minimise damage that could be caused to the poultry and the drawers, all lids are constructed from Stainless steel and are hinged to allow for easy access and maintenance, the lids are secured in such a way as allow access for only engineering staff.
  • To make cleaning and maintenance easier a GRP walkway complete with safety handrail is fitted to the top of the conveyors.

Drawer Turn Unit

  • The turn unit is of a pressed stainless steel construction.
  • To minimise damage to the drawers they will be driven through 90 degrees by being driven from the underside, this guarantees that the drawers are being pushed/driven on their strongest point and not the more flimsy top edge.
  • The drawers are driven on an acetal modular belt with drive bars to ensure a smooth transfer through the 90° turn unit.

Drawer Accumulation

  • The accumulation conveyors use twin uni-flex side flexing plastic chain, it is used due to its strength, durability and reliability, it has excellent wear characteristics and is virtually maintenance free.
  • The main conveyor frame and support legs are constructed from galvanised mild steel.
  • All the lids on the transfer conveyors are fixed from the top to minimise damage that could be caused to the poultry and the drawers, all lids are constructed from Stainless steel and are hinged to allow for easy access and maintenance, the lids are secured in such a way as allow access for only engineering staff.
  • To make cleaning and maintenance easier a GRP walkway complete with safety handrail is fitted to the top of the conveyors.
  • The length of the accumulation conveyor is tailored to the speed requirements of the live bird system, the faster the system the easier it becomes if there is a reasonable amount of accumulation.

Hang-on Conveyor, Hang-on personnel stand;

  • The basic construction and chain specifications are the same as the transfer conveyors, however where the personnel work is left open to allow for the staff to retrieve the birds and hang on the overhead line.
  • The conveyor is traditionally driven in the opposite direction of the line to allow for easier hanging and bird placement.
  • The foot stand is designed to allow a minimum 800mm per person and is 800mm deep it is accessed via steps with an interlocking gate at the top to reduce trips and hazards, the stand construction is galvanised mild steel with a GRP non slip grating platform, this is easier to clean and creates less stress on the feet and legs of the operators.
  • The end operator uses a knee switch to “call” for another drawer, as he is the last operator he ultimately hangs the last bird in the drawer

Drawer inverter

  • The drawer inverter is used to invert the drawers into a base up orientation, this initial inversion helps by shaking all the loose dirt from the drawer.
  • The inverter is constructed from a stainless steel frame with stainless steel access doors,
  • The inverter is constructed in such away so as backed up drawers cannot force the next drawer up and cause a jam.

Drawer washer infeed

  • The drawer washer infeed is the conveyor between the inverter and the drawer washer, this conveyor elevates the drawers to the correct level to infeed into the drawer washer, and this is variable and tailored to suit each customer’s site.
  • The drawers are taken up via a plastic modular chain fitted with “lugs” to positively drive the drawers uphill, however in the unlikely event of a jam up the drive motor is fitted with and electronic shear pin, this will cut the motor before any damage can be done to the drawers or the conveyor.

High level drawer wash

  • Constructed from stainless steel the draw wash which is approximately 3 metres long, the washer is fitted with gullwing doors to allow for easy access to the entire internals of the washer.
  • There are multiple spray nozzles fitted to easily removable jet banks, the nozzles are fitted in such a way so that they cannot be remounted in the incorrect orientation, this also allows for easy cleaning with little or no disruption to production.
  • The water for the drawer washer is handled by the water filtration system as listed in the module circuit.

Control;

  • Control for the system will be through a touch screen HMI mounted in the main electrical panel.
  • The panel will house all the electrical control equipment for the module circuit, along with the safety circuit monitoring system and control for the hydraulic lift.
  • A secondary satellite cabinet will be provided to house the drawer control and remaining pumps and filtration unit.
  • Whether motors chosen are hydraulic or electric they will all be fitted with variable speed control, providing optimum efficiency and speed for the system.
  • The control system can be networked view real time and historic data such as drawers per minute, downtime etc.

Pro Load Extras;

Module De-stacker & Re-stacker;

  • Modules are loaded onto the Pro-Load system in singles where speed and fork truck movements are not an issue, however, to reduce the number of fork lift movements we can install a module de- stacker.
  • The de-stacker enables the fork truck to load the Pro-Load system two at a time, one on top of the other, as they are transported.
  • The double stack module is transported along the infeed conveyor to the de-stacker, which lifts the top module off and allows the lower module to move further into the system.
  • The top module is then lowered onto the infeed conveyor to continue along behind.
  • The re-stacker works in reverse, once the module has been reloaded with drawers, where the fork lift can reload the truck two at a time.

Drawer Dip Tank;

  • Fabricated from stainless steel sheet the dip tank can be built to suit space available, the tank is fitted with multiple drain doors and associated pipework for filling and level control.
  • The dip tank outfeed can also accommodate a pre-wash unit that can house either high pressure jets or a flood type system again this can be made to suit environmental and customer needs.
  • The tank can be fitted with air agitation units, motorised brushes as well as chemical dosing.

Drawer Re-loader;

  • On faster systems an automatic drawer re-loader is often desirable.
  • This automatically accumulates the drawers after the drawer washer and reloads them into the washed modules.
  • This unit takes the drawers stacks them in the desired amount and pushes them back into the module using a hydraulic or pneumatic cylinder depending on system specification.
  • On systems using 4 and 5-tier modules and auxiliary sensor is fitted prior to the drawer re-loader so that it can stack the required amount of drawers.

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