Mayfield Laboratories
鈥淚t鈥檚 been tremendous!鈥
Production consultation enables 25% productivity improvement at Mayfield Laboratories
Mayfield Laboratories is part of Natural Looks Trading Ltd., specialising in luxurious, naturally inspired toiletries, fragrances, hair and skincare products. Their complete range is manufactured at their UK factory, and their distribution footprint extends worldwide.
After over 35 successful years in business, their next phase of growth is being masterminded by Peter Darke; an industry professional with experience in defining and developing manufacturing operations.
Peter consulted with Dean Willis, Sales Director of Adelphi Manufacturing, in his quest to refine the existing operational processes at Mayfield Laboratories, to increase efficiency and improve the overall flow and productivity鈥
鈥淚鈥檝e been doing this for quite a few years now!鈥 laughs Peter, 鈥渁nd to be subjected to hard-selling of machinery and equipment is really unpalatable. I prefer to use my network of experienced contacts to support my own knowledge, and help me to achieve the desired improvements.鈥 Peter appreciates that Dean has 鈥測ears of experience looking at machines and assessing what you can do to improve.鈥
Dean and Peter have each amassed over 30 years鈥 worth of know-how in the cosmetics and personal care process and packaging industry, and enjoy a good rapport, jovially reminiscing about shared industry events and contacts. As a result, Peter appreciates and values a high level of service and sound, actionable advice. 鈥淚f you just sell, without support, you won鈥檛 last long鈥, he declares. With Adelphi Manufacturing celebrating their 75th anniversary in 2022, this certainly isn鈥檛 the approach they have chosen!
Improvement 1
Fill Speed Adjustment
At his initial consultation visit in 2021, Dean encouraged Production Manager Kate Reeley to increase the filling speed at which the team were running their Adelphi Manufacturing Response Benchtop Fillers, to counteract the unsightly air pockets which were appearing in a body lotion.
This also had the benefits of improving the consistency of filling weights, and increasing throughput from 16 bottles to 25 bottles per minute; over 500 additional bottles per hour!
Kate鈥檚 verdict? 鈥淲e noticed the improvements straight away. We get much more out of the machines than we did before. We use them every day, there鈥檚 always one or two 搁别蝉辫辞苍蝉别鈥檚 谤耻苍苍颈苍驳!鈥
At Dean鈥檚 follow-up visit in 2022, Kate demonstrates a men鈥檚 shower gel product, which now has 1,000 units fully processed and ready to ship in the time he is conversing!聽
Improvement 2
Hopper Adaption, Electrical Sensor
General Manager Lucy Poole praises the improvements made by the hopper adaptation which Dean suggested at his initial consultation visit; an electrical sensor, which senses when the amount of product in the hopper is getting low, and automatically tops it up from the feed drum.
She recounts how Mayfield Laboratories implemented this with one hopper initially, to prove the concept, describing the outcome as 鈥渇antastic!鈥 She enthuses that the Response is now the team鈥檚 favourite machine, above any which were previously preferred before Dean鈥檚 advice was taken on board.
The benefits of this adaptation are threefold:
鈥⒙ 聽Safety: less traipsing up and down a ladder to fill the hopper, for operators!
鈥⒙ 聽Hygiene: avoids double-handling of the product when feeding the filling machine.
鈥⒙ 聽Efficiency: improved use of time, can leave an operator free to assist production elsewhere.
Lucy also mentions that 鈥渢he single-shot fill on the Response is much higher,鈥 and it can therefore fill much more of the Mayfield Laboratories range than previously believed. This includes potentially challenging high viscosity body scrubs; traditionally a slow fill. Dean is quick to boast, 鈥渢he machine runs well on scrubs鈥, and Lucy counters 鈥渋t runs well on everything!鈥
Assistant Supervisor Julia adds: 鈥測ou can rely on them more than any other machine 鈥 you set the fill volume, and once you鈥檝e got it there it stays there. They鈥檙e also easier to strip than any other machine we have.鈥 Minimal downtime for stripping and cleaning is crucial, as Mayfield Laboratories fill batches of anywhere from 500 鈥 10,000, with their incredibly varied range of container and product types.
Improvement 3
Preventing Product Waste from Nozzle Dripping
At his return visit in 2022, Dean helps to iron-out an issue with a silica-based anti-frizz hair serum, which had been dripping in between fills, unnecessarily wasting product. Although the sticky product caused some initial challenges, the correct solution was found and all parties have been pleased with the resolution!
The Overall Verdict?
鈥淚t鈥檚 made a huge difference,鈥 says Peter. 鈥淭here鈥檚 been a real step forward since Dean came in and helped, it鈥檚 been tremendous.鈥 鈥淭hroughput is so much better since Dean鈥檚 training and adjustments 鈥 around 25% more productive overall.鈥
Providing what Peter calls 鈥渂itesize chunks of improvements鈥 has resulted in a wish list of actionable points for Mayfield Laboratories, which the team can regularly revisit and analyse in terms of the costs and benefits of each, and the achievable next steps.
Lucy adds that Adelphi have provided 鈥渙ngoing support as the business is growing,鈥 saying 鈥渋f we鈥檙e bringing out a new product, we know we can ask your advice about how best to fill it 鈥 we can always pick your brain!鈥
Founded over 35 years ago, Mayfield Laboratories remains a family owned and run business. During this time they have built a wealth of experience and have an enviable reputation within the industry, priding themselves on delivering consistently high quality solutions and customer care.
Now heading for further ISO and GMP certification, the whole team at Mayfield Laboratories demonstrate an impressive culture of continuous improvement. They have taken on two extra units to help realise their expansion goals, and now employ their own in-house formulation chemist 鈥 the Mayfield portfolio boasts over 1,000 formulations to date!
Dean personally, and Adelphi Manufacturing as a company, are delighted to be assisting Mayfield Laboratories to achieve their business goals; offering responsible advice which enables businesses to weigh up the cost, output and operational improvement benefits and make well-informed decisions to enable sustainable future growth. We look forward to continuing this relationship long into the future.
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