Adelphi Group

Tristel Solutions

70% Productivity Boost for Global Disinfectants Manufacturer.

A large factory filling machine on a white background. The machine is metal, with a flat surface on the lefthand side, with a number of small white containers standing on it, to then be filtered into the larger box area in the middle of the machine. The large central part has a blue tint screen around complicated mechanisms, where the filling takes place. On the righthand side of the box area is a slim mechanical belt, where the containers will end up in a neat line, to go onto the next step of the process.

Tristel Solutions – a global supplier of infection control, contamination control, and hygiene products, serving hospitals worldwide (NHS and private).

Challenge

Tristel produces a dual-component disinfectant (base + activator) in conjoined bottles. Previously, the base and activator were filled on separate machines, capped individually, then combined with a dual activation cap before labeling – a manual and time-consuming process.

Solution

  • Response Automation Filling Line
  • Fed from two large tanks (one for base, one for activator).
  • Both components fill conjoined bottles simultaneously.
  • Integrates Tristel’s existing benchtop units, keeping prior investments in use.
  • Handles multiple product ranges, including the 500ml chlorine dioxide foam-based dual product.

Modular & Scalable:

  • Additional benchtop units can be added easily to increase output without extra cost.
  • Semi-automatic operation possible if a benchtop unit is removed for maintenance.

Results

Productivity:

  • 70% increase in output immediately after installation.
  • Producing 700–1,000 bottles per hour, depending on the product.

Reliability & Versatility:

  • Based on long-standing trust in Adelphi’s equipment: durable, low-maintenance, and dependable.
  • Modular design ensures flexibility and minimal downtime.

Rapid Response to Demand:

  • During the COVID-19 pandemic, Tristel added four more Response Benchtop Fillers, bringing the total to 10.
  • Machines delivered and operational within 4 working days.
  • Focused production on key disinfectants: DISTEL (hard surface cleaner) and JET (sporicidal disinfectant effective against SARS-CoV-2).

Customer Feedback

“The addition of automation has saved us a huge amount of time. We’d like to automate more packaging processes across the business.” – Jenny O’Callaghan, Production Manager

“We can trust these machines to run as we need without constant breakdowns. Quick support and easy scalability make them invaluable.” – Peter Twelftree, Production Engineer

Key Takeaways

  • 70% productivity boost with minimal new investment.
  • Scalable, modular, and reliable automation.
  • Quick delivery and responsive support for changing production needs.
  • Proven capability to meet high-demand scenarios like the global pandemic.

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