When Skegness-based Micronclean — a family-owned leader in specialist laundered garment services — found their existing packaging line failing, they required a solution that met the stringent hygiene standards of the pharmaceutical sector. With a legacy of innovation dating back to the 1920s, Micronclean needed a partner capable of delivering more than just an “off-the-shelf” machine.
The primary obstacle was the physical environment. Micronclean required a flow wrapper that could operate across two distinct hygiene zones: a Level 6 cleanroom for product loading and a Level 5 cleanroom for the final sealing and discharge.
Critical requirements included:
Segmented Installation: The infeed had to be situated in the Level 6 zone, while the main sealing assembly and machinery body resided in the Level 5 zone.
Bespoke Film Placement: To maintain strict protocol, the film reel needed to be positioned under the infeed within the Level 6 area, requiring a complete mechanical redesign of standard film paths.
Obsolescence: The competitor’s machine previously in place suffered from frequent breakdowns, causing costly downtime in a high-stakes pharmaceutical environment.
Record Packaging Systems Ltd facilitated a direct technical consultation between Micronclean’s team and our Italian manufacturing plant. This allowed their technical directors to collaborate directly with design engineers, ensuring every millimetre of the machine was fit for purpose.
Technical Specifications & Bespoke Engineering:
Inverted Design: The machine was engineered as an inverted flow wrapper, which is ideal for handling soft, irregular items like folded garments.
Box Motion Long-Dwell Jaws: We utilised box motion technology to provide a longer sealing time, ensuring a hermetic seal—critical for maintaining the sterility of cleanroom garments.
Relocated Reel Holder: In a feat of custom engineering, the reel holder was moved to the far end of the infeed to comply with the cleanroom’s spatial and hygiene constraints.
Full Wash-down Construction: The entire unit was manufactured from high-grade stainless steel with a flat belt infeed and best-in-class electronics to withstand rigorous pharmaceutical cleaning regimes.
The installation process was uniquely challenging. Our engineers worked simultaneously at opposite ends of the machine, separated by cleanroom glass. Communication was conducted through the partitions to ensure the machine was perfectly aligned across the two rooms. Despite these logistical hurdles, the installation was completed on time and to the exact cleanroom specifications required.
Micronclean opted for the Record solution specifically because of our ability to provide a bespoke, engineered system rather than a compromised standard model.
Key Outcomes:
Elimination of Downtime: The unreliable competitor machine was scrapped immediately and replaced with a robust, industrial-grade system.
Total Compliance: The machine successfully operates across the Level 5 and 6 cleanrooms, maintaining the integrity of the garments.
Long-term Partnership: Following the successful £160,000 installation, Micronclean signed a comprehensive service agreement, trusting Record Packaging with all ongoing technical support and after-sales care.
