Typical speeds for 200g and 500g bags are around 100 and 70/min respectively with accuracy to within 0.5g of target weight. As the weighers are operating well within their capacity, they’ll be able to support the business as it continues to grow and expand.
Onion Specialties is a relatively new player in the worldwide market of crispy fried onions but the management team has extensive long-term experience, with MD Bert Schot having worked in the industry for over 30 years. It’s hardly surprising, therefore, that within one year of starting production, the company is already 50% ahead of target, achieving sales not only in core markets of Europe and North America but also further afield in Brazil, Chile, Japan, China and Indonesia.
The Ishida weighers are currently operating a single shift, five days a week, but have the capability to increase output as the business expands. One weigher is handling the smaller weights into bags while the other operates multiple dumps to fill the large-size bulk packs.
‘The weighers have proved to be extremely consistent and reliable,’ comments Bert Schot. ‘They’re easy to operate with set-up and changeovers carried out at the touch of a button.’
Fast and reliable – Ishida’s perfect combination
A couple of thousand kilometres away, Ishida Atlas economy range ECO (Integrated Packaging Systems) are providing the necessary flexibility to handle high production throughputs at Russia’s largest snack producer.
The KDV Group is a leading Russian confectionery, bakery and snack food manufacturer, producing a variety of confectionery products under the Yashkino brand.
Consistently high demand for Yashkino confectionery led the company to extend its sales geography, with the establishment of new production facilities in different parts of the country, and today the KDV Group comprises 11 factories, producing over 350 types of confectionery products (waffles, biscuits, marshmallow soufflé, gingerbread, caramel and chocolate) and snacks (croutons, potato crisps, pellet chips, dried fish, seafood, sunflower and pumpkin seeds, and packed nuts), under 15 brand names.
Just as important as quality ingredients is a commitment to using only the best processing and packaging equipment – from Heat & Control and Ishida respectively.
The partnership between KDV and Ishida dates back to the early 2000s, when KDV acquired a snack factory where Ishida equipment was already installed. It was the accuracy and reliability of these machines that convinced KDV to continue using Ishida equipment.
As a part of a new potato crisps packaging line, specifically designed in conjunction with Heat & Control processing equipment, Ishida bagmakers work to full capacity and maximum efficiency.
From the start, the Ishida bagmakers were able to demonstrate flexibility and adaptability. During installation, KDV decided it needed to pack a wider variety of target weights than initially specified. Ishida engineers solved the problem with the introduction of special forming tubes for different types of bags, giving KDV the ability to introduce new bag sizes or product varieties without major additional investment.
The Ishida packing line comprises a 16-head Ishida multihead weigher integrated with the Ishida Atlas ECO snack food bagmaker that achieves high speeds even for difficult products such as potato crisps. The weigher operates in twin mode, with two sets of eight heads weighing the snack products simultaneously, at speeds up to 95 bags/min/side.
The Atlas bagmaker incorporates a single rotary jaw motion and superior control technology, which minimises product waste, film loss and downtime for film changes. An innovative sealing unit creates tight horizontal and back seals without wrinkles even during high-speed packing. The Atlas also effectively controls product charge, reliably stripping any remaining product from the seal area and preventing product from being blown upward. The overall efficiency of the line is around 98%.
Pressure, temperature and sealing time can be set by remote control Unit to match production speed and film characteristics, creating optimum seals for any film.
The bagmaker’s user-friendly and easy-to-maintain design is simple to set up and operate and an auto film splicing feature reduces product changeover times by up to 10%.
Currently the four Ishida bagmakers at KDV are handling a variety of leading brands, including Crispy Potato, Pro Chips and Fun Chips in pack sizes ranging from 40g to 160g. Across the four lines, the machines pack 20 tons of product in every shift, with giveaway never any more than 2% of target. On a 65g bag, for example, deviations range from just 0.5g under to 0.7g over.
Reliability has been excellent with KDV reporting no breakdowns since the lines first began operating in 2012. Currently the factory operates five days/week in 10-hour shifts but during high season it runs 24 hours.
Thanks to ease of operation and easy cleaning features, product changeovers take no more than 15 minutes. Another benefit of the twin design is that one side of the weigher is able to continue to operate while the film is being changed on the other, meaning production can be maintained and throughput maximised.
‘Undoubtedly the major benefits of the Ishida bakmakers are their excellent reliability and high productivity that allow to us to respond to market demand for our products,’ comments Vladimir Grankin, KDV Group’s technical director.
‘In terms of technical support during the installation and operator training, the level of service is excellent. The bagmakers are easy to operate and maintain and this is another key advantage for us. The ability to fully automate the weighing and bagging process has enabled us to further enhance the quality of our products. Indeed, thanks to the success of our relationship, we only develop new projects with Ishida,’ he concludes.
It’s no surprise, therefore, to learn that the company is already in discussion with Ishida for a number of new developments for both snacks and confectionery.