Innovation Leads the Way at Kenray

Kenray has invested in Research and Development in recent years with support from Phill Loxley, our Head of Engineering. This has enabled us to be the industry leader in developing technical solutions for the Packaging Industry. Over recent years, our R&D skills have proved invaluable to leading Blue-Chip clients transitioning to sustainable & compostable film structures that have allowed them to alter packaging configurations and material usage whilst maintaining product outputs on VFFS & HFFS machines.

Phill Loxley, has been instrumental in this development and has been at the forefront of this project and many others. Phill has worked closely with OEM’s & end-users to understand the challenges they are facing.  He has then designed and manufactured a number of innovative solutions along with his team of Engineers that have consistently been recognised by clients. An inventor at heart, the pioneering solutions that we have been able to help companies adopt have made huge impacts such as reduced Nitrogen usage, reduced wastage and improved overall efficiencies.

Andrew Dennis, Technical Director added: “Working closely with Phill, you can see his patience and diligence come through to help clients overcome complex machinery challenges. We are delighted to have been chosen as a partner of choice to help design and develop solution’s over the past few years and with the future expansion plans in place, this capability can only strengthen our product offering.”

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Kenray Video: Stick Pack Forming Set Solutions

Kenray Forming Ltd – Stick Pack Solutions

I’m Mark Evans from Kenray, today we are in the engineering office and I’m going to look at how we produce Stick Pack Formers.

During the first stage, our Engineer will find all the specifications and input them into the model.

The software itself will look for any errors. Once this process is complete the model itself will generate the forward engineered patterns.

Here you can see the typical Stick Pack Former, which has been through this process.

Once this former has been digitally developed, it can be placed together with other formers into the requisite number of lanes.

The next step in the process is to generate the machine tool program using 3D Graphics simulation.


The final part of the process is these images are sent to the machine shop for Machining. Here you can see a stick pack former being milled.

So I hope that gives you some insight into how we prepare and manufacture our stick pack formers.

Thank you for listening. Please contact us on +44 (0)1530 400 100 or email [email protected]

Kenray Video: Our Engineering Department

Kenray Forming Ltd – Welcome to our Engineering Department

Here we are inside the engineering office.

In total, we have nine Engineers, three of whom are dedicated to research and development.

Here you can see one of the designers who is scanning a customer’s, pattern you will then scan them into the computer and check it against our forward engineered models.

Here you can see one of the designers using a 3D CAD cam. Once the model has been completed it can be sent across to production to be cut on a 3-axis machine.

The Development Department also has a dedicated, highly skilled Fabricator who can turn ideas into products. Here you can see a Kenray redesign of an original part being tested.

Please contact us on +44 (0)1530 400 100 or email [email protected]

Kenray Video: Our Site 3 Testing Facility

Kenray Forming Ltd – Welcome to our Site 3 Testing Facility


Today we’re looking at our Testing Facilities that we have available here on Site 3.

This Kliklok Woodman Intermittent Machine can be used with either a vacuum or a friction drive facility.  To test TNA and other front drive formers, we have a TNA Robag 3 in our line-up.

Our line equipment LE 400 machine has the ability to test all Doy & Quad formers. All continuous high-speed formers can be verified on this apparatus.

Here we are at the back of the machine and the first thing we’re going to do is to ensure that the reel is correctly positioned on the machine and the film is running true and will be aligned to the bag specification.

So, here we are at the front of the machine all we want to ensure is that the film is running smoothly over the shoulder and touching at every point. will also want to make sure the geometry is correct, and everything is lining up.

Okay so the final point of the process is to check that we’ve got a good bag of the machine First thing to do is to make sure that we got the right bag size, check that we’ve got the correct seal and seal is actually strong enough and then finally check for creases, wrinkles and any twisting.

Please contact us on +44 (0)1530 400 100 or email [email protected]