Background
A prominent fruit manufacturer specializing in fresh produce sought an innovative and automated solution to streamline their packaging process for cherry tomatoes and blueberries. The primary objectives included improving operational efficiency, reducing manual labor, maintaining accurate product weights, and ensuring high-quality packaging consistency and freshness. Manual packaging processes were proving inefficient, time-consuming, and error-prone, which highlighted the urgent need for an automated solution that could keep pace with growing production demands.
Opportunity & Implementation
Smartpack, known for its expertise in advanced packaging automation, designed and delivered a fully integrated clamshell packaging line tailored specifically for handling delicate fruits such as cherry tomatoes and blueberries.
The comprehensive, turnkey system provided by Smartpack included the following key components:
Clamshell Denester:
- Automatically separates and accurately positions clamshell containers onto the conveyor system.
- Capable of smoothly handling various clamshell sizes with minimal downtime and adjustments.
- Designed for ease of loading and continuous operation, significantly reducing manual intervention.
16-Head Linear Weigher:
- Offers precision weighing and rapid product dispensing, ensuring each clamshell contains the exact targeted weight.
- High-accuracy sensors minimize product giveaway and optimize efficiency, crucial for maintaining profitability.
- Configured specifically to handle the gentle nature of cherry tomatoes and blueberries without causing bruising or damage.
Clamshell Closing and Sealing Machine:
- Efficiently and securely closes and seals the filled clamshell containers.
- Ensures airtight sealing, preserving product freshness, extending shelf life, and maintaining an attractive, market-ready presentation.
- Features adjustable settings to accommodate various clamshell dimensions, enhancing versatility.
Design Features & Specifications
- Tray Handling Capability: Supports multiple standard clamshell sizes typically used in the fresh produce industry, facilitating flexible production runs.
- Operational Speed: Capable of processing and packaging up to 160-180 trays per minute, dramatically increasing throughput and overall productivity.
- Weighing Accuracy: Equipped with a state-of-the-art linear weighing system, Smartpack ensures exceptional weight precision and consistency, significantly reducing product waste.
- Construction and Durability: Built from robust stainless steel and food-grade materials, ensuring hygiene, easy cleaning, and long-term durability.
- Power Requirements: Compatible with standard electrical systems (220V, 50/60Hz single-phase power), facilitating straightforward integration into existing manufacturing setups.
- User-Friendly Controls: Incorporates an intuitive, centralized control panel that simplifies machine operation, routine maintenance, adjustments, and troubleshooting. This design helps minimize training requirements and reduces the potential for operational errors.
Results
The deployment of Smartpack’s automated clamshell packaging solution provided transformative results for the fruit manufacturer:
- Significant Efficiency Gains: Achieved higher production throughput, enabling the manufacturer to meet growing market demands.
- Consistent Product Presentation: Automated processes delivered uniform packaging, enhancing product marketability and customer satisfaction.
- Labor Cost Reduction: Substantial decrease in manual labor dependency, enabling staff to be reallocated to higher-value tasks.
- Improved Freshness and Reduced Waste: Secure and airtight sealing improved product shelf life, reduced spoilage, and minimized costly product returns.
The implementation of Smartpack’s fully automated system allowed the fruit manufacturer to strengthen their competitive position in the market by achieving a higher degree of production accuracy, reliability, and scalability.
For additional information or to request a personalized consultation and quote, please contact Smartpack directly at info@smartpackmc.com.