RGE – NEWS AND UPDATES

What are Wheeled UDPs?

Wheeled Universal Display Pallets can be used to move stock or products around factories, or load pallets on and off vehicles without the need for additional material handling equipment. Wheeled UDPs support heavy loads making it easier and safer to move goods. Using wheeled pallets cuts staff handling time and reduces the risk of product damage. Alternatively, the Wheeled UDP can also be used on the shop floor to display goods and speeds up replenishment of stock on the shelves, and when used in conjunction with our MultiNest Crates allows for stock to be moved safely around retail areas. Wheeled UDPs are reusable, and are designed to last.

Why use Wheeled UDPs?

Plastic Wheeled UDPs are ideal for transporting goods or small containers around distribution centres and factory floors, as well as around retail spaces. The pallets are able to support heavy loads whilst remaining easy to move. This makes it fast and easy to transport goods without the need for additional equipment, as opposed to pallets without wheels. The pallets can also be stacked on top of each other for a more convenient storage option.

When used within retail spaces, the Wheeled UDP can be used to display products on the shop floor. Boxes of product can be loaded directly onto the pallet, allowing brands to have their packaging on display to customers, increasing product visibility and therefore increasing sales and brand recognition. This makes the Wheeled UDP ideal for promotional use, in store marketing and displays. The RGE MultiNest crate can also be used alongside the Wheeled UDP to store and display items, such as fruit and vegetables. The crates can easily be swapped out on top of the Wheeled UDP, and the whole pallet is able to be moved around the shop.

The fully recyclable plastic used is well suited to withstand large loads, and remains strong and stable for the safe handling of all goods. The structural integrity of the RGE Wheeled UDP reduces the possibility of damage to products, which could be caused by splinters or damage to wood over time from consistent use of wooden pallets. The plastic used is also suitable for the transportation of food, and can easily be wiped clean if it comes into contact with liquid. The pallet also allows for access to the product from any of the four sides, whilst holding them in place with retractable pop ups.
 

RGE’s Wheeled UDP

The RGE Wheeled Universal Display Pallet is a strong and durable plastic pallet, designed for multiple applications. The Wheeled UDP is a solid deck, half euro sized pallet. It is lightweight and has been designed specifically to aid easy handling and movement without the need for a pallet/pump truck. The pallet features retractable pop ups to secure loads and aid the use of crates.

RGE’s long lasting Wheeled UDP is made from a recycled and virgin polypropylene base and can be completely recycled. Because the pallets are made from plastic, they are significantly more durable than wooden alternatives, and prove to be more sustainable and environmentally friendly in the long run, as they are less prone to breakage and damage, and can be recycled after use. The pallets are stable, safe, can be easily stacked and handle high loading capacities. The Wheeled UDP works in conjunction with RGE MultiNest Crates to effectively move and transport produce and goods more easily than traditional standard pallets. RGE’s Wheeled UDP is available in black with red pop ups, but can be produced in other colours upon request. The load capacity is 250kg, and the pallet measures 800 x 600 x 200mm. The Wheeled UDP is also available with a fitted break for enhanced safety.
 

The RGE Whittlesey site is our largest manufacturing site housing nearly 50 injection moulding machines with an impressive range of 35t – 3,150t clamp force. We have been investing in a number of new machines and site improvements over the past year to increase our capabilities and meet customer demands. In this article we are focusing on our vibration welding, CNC routing and 2700 Tonne injection moulding machines which have recently been installed at our Whittlesey facility.

CEMAS 999 Vibration Welding Machine

Vibration welding is an effective solution for welding plastics as it uses frictional heat to create precise and extremely strong seam joints between plastic components, with good aesthetic results. Our new CEMAS welding machine can be used to weld pallets, large dashboards and outdoor furniture. The machine is currently being used at our Whittlesey site for the production of heavy duty pallets with an impressive dynamic load capacity of 3000kg, a racking load of 1500kg and a static load of 4500kg. The production of these pallets involves the use of a 6-axis robot to place firstly a polypropylene base, followed by a metal frame, and then a polypropylene lid into the welding machine. The plastic lid and base are held in contact under pressure and vibrated so that the edges to be welded rub together, creating frictional heat and welding the plastic pallets around the metal frame. Our CNC routing machine is then used to smooth the rough edges of the pallet.

The CEMAS 999 machine can accept up to 200kg in upper tooling weight and exert a clamp force of up to 36KN.

Technos HD 3015 CNC Machine

Computer Numerical Control, or CNC machining, is a high-tech manufacturing process that pre-programs computer software to direct the movement of machines to produce and handle very specific tasks. The newly installed Technos HD CNC Machine is currently used in many of our customer projects here at RGE. We are also looking to update the design of our Datum writing tablet, which will involve manufacturing and cutting our wooden tablets in house, incorporating the use of this machine. The machine’s eight-position tool rack allows for a wider range of tooling options when machining and speeds up production time. Its servo motors are controlled from premium servo drives to ensure accuracy every time with rapid axes speeds of 50mm/min.
 

Negri Bossi Bi Power 27000H-41080 with six axes robot

The Negri Bossi 2700 is a two-platen injection moulding machine with 27000 KN clamping force, a reciprocating screw with electric screw rotation, and an injection capacity of 21790 cm3. It is currently being used to mould 1200 x 1000 pallets. The machine is specifically designed to provide consistent melt quality of recycled material. The unit is equipped with a 6-axis robot which can remove parts from the machine, stack parts and then push them along the assembly line.

Here at RGE we have made some major investments at our white goods factory site in Yate (Bristol), where we supply finished key moulded components direct to our customer’s assembly line on site. These investments have allowed us to streamline production in the factory, increase efficiency and reduce costs.
 

New Borche Injection Moulding Machines

An investment in excess of £1 million was made of four new Borche machines, including two new Borche BU700 ton machines along with a new 120 ton machine installed at our Yate site, with the remaining machine (BS60) installed at our Whittlesey site. The machines came complete with Sepro robots together with the latest associated ancillaries.

Why such an investment?

RGE decided to make these investments with the aim of speeding up production, improving energy savings and reducing costs.
 

What attracted RGE to this equipment?

The new Borche BU700 ton machines are of the Two Platen design which are very compact in terms of machine footprint. The machines also employ Servo Motor Drive technology which reduces power consumption together with water cooling requirements. These machines are therefore extremely energy efficient and this was a major factor of influence in making the decision to choose Borche. The machines are also equipped with the Auto Tie Bar removal system for ease of tool loading.

“We are delighted with the performance of our new Borche machines and for delivering the necessary energy savings that we require” Dan Leach, RGE Group Managing Director
 

What projects have resulted from the investment?

In combination with these machines, a conveyor system has been installed at the Yate factory site. The conveyor unit runs from the machines, directly through to the printing room. In this way, moulded parts can be delivered with ease straight to the operators in the printing room. This has therefore reduced handling, travel time/distance, packaging and stock holding, all of which has further increased efficiency on site.

Further projects at the Yate factory

In partnership with our white goods customer, there has been a 750k investment in an automated washing machine tabletop gluing line. The machine is used in combination with a six-axis robot, and has the impressive capability of gluing 1 part every 12 seconds.

Another bespoke machine has been installed to aid a manual process of inserting magnets into washing machine plinths. The new machine acts as a wheel which, upon each rotation, presents a new plinth to the operator. The machine will only rotate again once it has detected that the relevant magnets have been properly inserted, which therefore ensures quality and improves efficiency of production.

RGE continually looks at new ways to improve its facilities in order to enhance efficiency and reduce costs, without cutting on quality.

Pallet collars are widely being used in the packaging and distribution industry. But what exactly are pallet collars? Why should your business be using them? And what are the benefits of using plastic pallet collars over wooden ones? 
 

What are pallet collars?

Pallet collars are an accessory to flat pallets, offering a more efficient packaging solution than traditional wooden boxes. They consist of 4-6 panels which are placed on top of wooden or plastic pallets, transforming them into complete storage/shipment containers.
Pallet collars can be securely stacked on top of each other to increase height, allowing for the storage of more items on a single pallet. They can also be easily collapsed when not in use, saving valuable storage space.
With RGE’s plastic pallet collars, you can customise the colour and print your logo to suit specific branding requirements.
 

Why use pallet collars?

The versatility of pallet collars allows them to suit various business needs and provide a variety of benefits as a packaging solution. Some of these benefits include:
 

Quick and safe order preparation

For many companies, orders are constantly being received and need to be despatched very quickly. Every minute is crucial to ensure that orders arrive on time and customers stay happy. By using pallet collars, it allows your employees to stack and access products efficiently and safely. Time is not wasted on finding the right sized box for the order. The pallet collars can easily be built up as products are stacked, achieving your desired height until the order is ready.
The stacking ability of the pallet collars also means that they are safer for your employees, as the quick and easy height adjustment of the packaging eliminates the need to bend over high bin sides, reducing pressure on a worker’s back.
The collars can be assembled, collapsed and folded within seconds by just one person, with no need for tools. They’re also lightweight and easy to handle.
 

Space saving design

Unlike traditional wooden boxes which take up a lot of room, pallet collars can be collapsed and folded, taking up little space. This flexible design allows you to save up to 80% of space, significantly reducing storage costs. Plus, the secure stacking ability of these collars means that you can ship more products whilst using less space. 

Eco-friendly packaging

Plastic pallet collars are a sustainable packaging solution;
Since the pallets can be used time and time again, unlike single-use cardboard or shrink wrap, it avoids the production of any packaging waste. Not only will this help your business to comply with packaging waste regulations, but it will reduce your carbon footprint too.
The manufacturing process of RGE’s plastic pallet collars requires around 40% less energy than that of cardboard, whilst also producing less waste.
RGE produces pallet collars from both virgin and recycled plastic. Once the collar has reached the end of its life, it can be fully recycled, making it a great option for eco-friendly packaging. 

Cost effective

The use of pallet collars can help your business to cut costs and save money. As previously mentioned, costs are reduced through saving space and minimising waste. Another way that using pallet collars can help your business to save money is through the protection they provide to your pallets and goods during the transportation process, reducing the risk of damage and cutting the costs of repairs and replacements.
The design of RGE’s plastic pallet collars means that individual panels can be replaced if broken, avoiding the need to pay for a replacement of the whole pallet collar.

Plastic pallet collars or wooden?

While wooden pallet collars make up around 90% of collars used around the world, plastic collars offer a variety of benefits that wood simply cannot.
Wood is seen as a sustainable resource for making pallet collars, however, RGE’s plastic pallet collars can be made from recycled materials and can also be ground down to be made into a new product when broken or no longer needed. Plastic pallet collars generally last longer than wooden collars and need to be replaced less frequently, whilst wooden collars are prone to splinters and other forms of damage which can be a danger to those handling the collars; plastic collars do not pose this risk. There is also the added benefit of plastic collars being lighter than wood, which is advantageous from a logistics point of view – the collars are easier to handle and move quickly, whilst remaining strong and durable.

Plastic pallet collars are easily cleaned and can be wiped or washed without damaging the collar. Wooden collars can be hard to clean, especially when wet, which can lead to fungus and bacteria growth in the wood. This makes wooden collars unsuitable for the transportation of food, drink and pharmaceutical goods. Wooden collars also require heat treatment before they can be used for international shipping, unlike their plastic counterparts.

RGE’s Regen Pallet Collars

RGE’s plastic pallet collars are helping a variety of businesses to cut costs and improve the efficiency of their packaging process. Our Regen collars are available in a range of colours (unlike wooden collars) and can be customised to suit your business needs and branding requirements. They are manufactured in the UK using recycled or virgin polypropylene material.
The Regen pallet collar is tough, long-lasting, and cost-effective. It is available in the following sizes:
1200 x 1000 x 300mm (UK pallet size), 1200 x 800 x 300mm (Euro pallet size), 1200 x 1560 x 300mm (Extended pallet size).


Pricing discounts are available when ordering in large quantities. Please get in touch with a member of the RGE sales team for more details – sales@rgegroup.com

Introducing the Ephgrave Chair

Caroline Ephgrave has worked as a physiotherapist for over twenty years, and began developing her own office chair, uniquely designed to provide specialised support to the spine, six years ago. After training as a dancer with the Royal Ballet, Caroline studied to become a physiotherapist at King's College London. Caroline's background has provided her with an in-depth understanding of movement and biomechanics, giving her a unique perspective whilst searching for a solution to the common and avoidable back issues which can be caused by using office chairs.

Using an office chair is a big part of most people’s day-to-day lives that we barely stop to think about. Problems with your back or neck, however, are harder to ignore. Spending long periods of time at a desk can lead to poor posture and cause back problems, as the spine is adversely aligned and the load is not evenly distributed. The subsequent restriction in movement affects many aspects of life, such as struggling to lift things, or with exercise and sports.

The Ephgrave chair aims to prevent this and focuses on supporting the keystone of the spine, which holds the body in a more balanced position and prevents slouching. The chair has a single, convex, moveable cushion that can be positioned at the balance point (keystone) of the spine for each user. The level of the keystone differs between individuals according to their dimensions and postural habits. By supporting this bone in line with gravity, the ribcage and head are balanced over a level pelvis: joint load is centralised and muscles can let go.

The unique design and concept of the Ephgrave chair brings awareness to how we sit and provides a different approach to preventing and treating back problems with the use of a small, adjustable cushion, designed to support a single keystone area of the back, and thus the whole spine. The cushion, which was designed with RGE, is easy to use and can be adjusted to suit each user. In the same way that you instinctively know exactly where to position a cushion behind you when sitting on a sofa, the adjustable curved cushion of the Ephgrave chair can be moved up and down, as well as forward and backward, so that the user can find the perfect position to support the correct parts of the back and improve posture. The domed cushion allows you to flex, arch and stretch your back throughout the day, mobilizing the stiffest joints in your back and improving overall mobility. Balancing the body also helps to release muscles in other places across the body, having widespread results.

The domed cushion was designed with RGE, and the original concept of an inflatable cushion was adapted to be more user friendly and provide better support. The curved cushion allows the chair to support the keystone of the spine, although it was a challenge to find the right curve and decide upon how firm the cushion should be whilst working virtually during Covid restrictions. The chair also allows and encourages the user to move – arm rests and huge cushioned backs can be limiting and cause you to twist in your lower spine as overall body movement is restricted.

RGE was able to help Caroline complete her vision for the innovative and distinctive design of the Ephgrave chair. Although it was difficult to work collaboratively during lockdown, Caroline was able to work closely with our designer Mark Temple. RGE provided support to amend parts of the initial design in order to create a more sleek and streamlined chair, moving the chair away from the initial aluminium prototype which was extremely heavy. Mark helped to design each part of the chair to ensure they fit together to create a cohesive and simple look. A lot of thought went into creating a chair that met the criteria for the dimensions of an office chair without it appearing bulky. Other parts of the chair also had to be decided upon, such as the finish and size of the back wings, mechanisms, clamps for the back cushion, alongside the logo and scale designs featured on the back of the seat. The length of the stem also had to be carefully designed and tested in order to meet the strength and dimension requirements to support any user. RGE sourced a bespoke gas lift specifically designed for the Ephgrave chair and used our in house upholstery team in our Lithuania factory to upholster the seat.

RGE’s Design team was able to help Caroline with a variety of the practical aspects of creating a chair that was both functional within an office setting, whilst providing the best support to the back. Mark worked with Caroline to further develop the original seat design to improve ergonomics, comfort and encourage mobility around the desk. The seat depth which is shorter than standard still provides support to body weight (as the body is balanced over the pelvis) but makes it easier to bring the chair in close enough to the desk to encourage use of the back support. Mark Temple kept the curved shape at the front of the seat with a waterfall edge for comfort. By choosing to omit arm rests, the chair is able to fit under the desk to allow the user to be closer to their keyboard without leaning forward, and also frees up the swivel action of the chair as arms often hit the desk. RGE have worked with Caroline to bring her innovative design into reality and since the products have been manufactured, RGE has stored them at their UK central distribution centre in Cambridgeshire where they are sent directly to customers.

Initially RGE began testing different materials for the parts of the chair, working towards passing tests and meeting classifications. The materials underwent strength testing and we trialed different compositions of glass filled nylon before we began making tools in order to put together prototypes of the new and improved designs of the chair in the UK. After the prototype was made, changes to the shape of the back of the chair to support the cushion were made, allowing the chair to balance the user correctly to help the foam  provide support.

The chairs have been manufactured and are now available to buy online at www.ephgravechair.com. Initial feedback has been extremely positive with users reporting increased comfort and flexibility at their desks. The chair will be exhibited at Clerkenwell Design Week (24-26^th May) in London.

Caroline’s comment:
“I’ve really learned from the experience of working with RGE. For me, it was invaluable having a team with in-depth knowledge and experience of chair design to help me bring my vision to reality. Throughout the process, we worked together to find the best materials and solutions to bring out the features of the design and ensure the chair supports the spine – so blending the best of style and functionality. I am delighted that we now have the chair in production and am very grateful to all at RGE who helped to make this possible.”