CASE STUDY: Spreader Rollers – Leading Online Retailer

Cottam was approached by a leading UK online retailer with a clear objective: to replace the standard bow rollers used in their packaging machinery. These existing rollers were failing to sufficiently reduce creases in plastic bags as they come off the coil. That issue prevented the robot arm from opening the bags for filling, causing line stoppages and requiring operator intervention, ultimately impacting line efficiency.

The customer needed a more effective and reliable solution that could be seamlessly integrated into their existing setup.

The Solution

After discussing the application and identifying the root cause of the issue, Cottam’s in-house design team proposed the use of our spreader roller. Unlike standard bow rollers, Cottam’s spreader roller uses thousands of fine bristles to gently stretch and spread the plastic substrate (in this case plastic bags) by tiny increments, effectively eliminating surface creases.

To ensure a smooth transition, the spreader roller was designed as a drop-in replacement for the existing roller, ensuring compatibility with the customers current machinery.

The Results

Two spreader rollers were installed and trialled over a four-week testing period; one on the standard bag line and one on the chiller bag line. The results were excellent:

  • Bags came off the coil smooth and crease-free
  • Integration with existing machines was seamless
  • Downtime was reduced, and manual intervention was no longer required

Impressed by the performance and build quality, the customer placed a full order to replace the existing bow rollers with Cottam’s spreader rollers. They also highlighted the high-quality packaging and overall product craftmanship as standout features.

”We’ve been thoroughly impressed, not just with the spreader roller’s performance, but also with the quality and care evident in its packaging. We have noticed a sharp incline in machine performance since the brush rollers were fitted, and we have been delighted with their performance. A fantastic product all round.”

ENGINEERING MANAGER, LEADING ONLINE RETAILER

Conclusion

This project showcases Cottam’s ability to deliver tailored, high-performance solutions through a collaborative design process. By replacing standard bow rollers with our adapted spreader rollers, we not only solved a persistent operational issue but also enhanced the overall efficiency and product quality for the customer.

The successful outcome led to a further rollout, reinforcing Cottam’s position as a trusted partner in brush and roller solutions for industry-leading businesses.

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