Background
ABC Company(ABC is replacing the real company name, to protect customer’s information) , based in Germany, operates within the agriculture industry as a medium-scale vegetable distributor. With a history spanning several years, the company has made a significant impact on the German market with its emphasis on providing high-quality, fresh produce.
Supplying rocket salad to supermarkets forms an integral part of ABC Company’s business model. They have established strong relationships with numerous large and small-scale supermarkets across Germany, becoming a trusted partner due to their unwavering commitment to quality and reliability. These partnerships have been vital in expanding ABC Company’s reach and reputation in the consumer market.
Despite operating at a medium scale, ABC Company handles a substantial volume of vegetables daily. Their commitment to ensuring the freshness and quality of produce means that they are constantly managing tight schedules and dealing with the logistical complexities of distributing produce to various supermarkets.
The company’s operations are characterized by the traditional manual labor model. This includes sorting and filling trays with an assortment of vegetables, a process which, while time-tested, has begun to present significant challenges.
Objectives
In the current scenario, ABC Company employs a team of twelve dedicated workers who manage the weighing and filling process of rocket salad into trays. This labor-intensive process, while being handled efficiently by the team, allows for a production capacity of approximately 20 trays per minute. This not only requires considerable time and effort but also relies heavily on the accuracy and speed of the workers. Additionally, the physical demand of the job combined with the repetitive nature of the tasks can lead to worker fatigue, which could potentially impact the consistency and quality of the filled trays.
The company is therefore in need of a solution that can automate or semi-automate these tasks, thereby reducing the reliance on manual labor. Implementing a machine that can automate this process would not only increase the speed and efficiency of the tray filling process, but it would also significantly reduce the labor costs associated with it.
The idea is to invest in a state-of-the-art vegetable tray filling machine that can revolutionize the current process. This machine should be capable of automatically weighing and filling the trays, reducing the number of employees required for this task, and in turn, lowering labor costs. This strategic move is expected to not only improve operational efficiency but also provide a more sustainable and scalable solution for the company’s future growth.
Packaging Solutions
Smartpack team offer us a salad multihead weigher with tray denesting machine solution.
This filling line with the automatic process including:
- Incline conveyor: auto feed the rocket salad to multihead weigher
- Tray denesting: auto picks & places empty trays
- Salad multihead weigher auto weigh and fill into trays
- Conveyor delivers the ready trays to next process
After 40 days for producing and test, 40 days for shipping. ABC company received and installed the tray filling machine in their factory.
Results
Since implementing the vegetable tray filling machine, the team employees reduced from 12 to 3, stable weighing filling capacity is 22 trays per minute.
The wage is 20 euros per hour for workers, it means that saving 180 euros an hour, and 180×8=1440 euros a day, save 7200 euros per week. Only several months, customer paid back the cost after using the machine for a few months. “It is really a huge ROI!”, said by the CEO of ABC company.
Moreover, this automated vegetables filling system is used in wide range of salad,it would also have the potential to scale up the operations to handle a wider range of salad in tray, thereby increasing the company’s production diversity.
Tray and pillow bags are popular package formats in vegetables industry. At Smartpack, we not only provide salad tray weighing filling machines, but also offer several models of vegetables packing machine in bags(multihead weigher with vertical form fill seal packaging machine) for fresh cut, cabbage, carrots, potatoes, or even fruit.
Customers have praised the design and quality of our devices, Smartpack engineer team also provide the overseas service to help customers for machine commission and operation training, take care of your worries. So now, share us your request and get solutions from Smartpack team! Contact or email us at info@smartpackmc.com!