Until recently, there was a real gap in the market for an affordable stainless steel flow-wrapper that could produce high quality packs efficiently and reliably in these difficult operating conditions.
But now a growing number of successful leek producers such as Allpress Farms and J Warnock have found a way to increase production line efficiency without breaking the bank - Ilapak’s new fully stainless steel Carrera 500 PC electronic flow-wrapper.
As well as boosting productivity, with speeds of up to more than 40 packs a minute, this compact flow-wrapper is built to withstand the harsh environment of a typical leek packhouse. So for the first time producers are finding that they can afford to upgrade from a standard painted machine and benefit from the vastly improved hygiene and performance standards of stainless steel.
Allpress Farms in Chatteris, Cambridgeshire, a top leek producer supplying some of the UK’s leading multiple retailers, was one of the first companies to discover the benefits of this new flow-wrapper when it was launched in early 2004.
With two Carrera flow-wrappers now operational, both part of fully automated weighing, washing and packaging lines, the impact on the company’s production line has been dramatic, helping to bring about an overall increase in productivity of around 25 per cent.
The Carrera flow-wrappers were installed as part of a £500,000 investment programme by Allpress, which also involved the construction of a new packing facility and installing additional production line equipment aimed at boosting productivity.
A key reason for this investment in new facilities was to meet the increasing demand from supermarkets for pre-packed leeks which are fast winning market share from traditional loose leeks.
Nick Allpress at Allpress Farms says: “Over the last couple of years, we’ve seen a marked change in demand from the supermarkets. The demand for loose leeks is decreasing by around five per cent while the demand for pre-packed leeks is growing by about 15 per cent. This has been a major factor in our decision to invest in new production facilities designed specifically to meet the growing requirement for pre-packed, rather than loose leeks.
“Because it’s fully electronic, the Carrera has enabled us to improve efficiency, with features such as no-product-no-bag cutting packaging waste and reducing costs by about 10 per cent. The line is fully automated, which increases production line efficiency while the machines are still very easy to use and reliable.
“The fact that the Carrera is now available in stainless steel was an additional advantage - it’s easier to wash down, won’t rust and ensures excellent hygiene standards in general. It’s also extremely competitively-priced.”
Pack quality is clearly another important issue and the Carrera 500 PC stands out for its ability to produce the type of high quality packs that are demanded by supermarkets and other large retailers.
Allpress adds: “The Carrera is capable of producing very high quality packs that draw the consumer’s eye to the product, packing the product in a uniform manner, with good quality seals that help to maintain freshness - in short, they help to produce a very saleable product.”
And it is this pack quality, again combined with a drive to enhance production line efficiency, that prompted another leading leek producer, East Lothian-based John Warnock, to go down the Carrera 500 route, first installing a machine with a paint finish and then, when it became available, a further stainless steel model.
The company, which has also seen a significant increase in demand for pre-packed leeks which now account for 60 per cent of its production, recently completed a major upgrading of facilities and equipment, reconfiguring its operation to meet this growing demand for pre-packed, rather than loose leeks.
They chose Ilapak both because it’s a well known brand and also because the company was recommended to them by another producer. According to Warnock, consistently high quality is vital when it comes to packaging and the Ilapak machines meet this requirement extremely well.
He comments: “Consumers are driving the demand for pre-packed leeks - they’re convenient, easier to handle and have a better shelf life. But pack quality is crucial and the Carrera flow-wrappers have enabled us to meet the highest standards. Seal quality is excellent and the machines allow us to produce the type of high quality packs that consumers expect.”
“When it comes to packaging, it has to be right first time - if it’s not, the pack is rejected and has to be re-done. So a machine that we can rely on completely is of the utmost importance to enable us to meet our quality standards and maintain high levels of productivity.”
He concludes: “The availability of a stainless steel machine is also an important advantage. Stainless steel is definitely the way to go - it’s hygienic, durable and much easier to clean down, which is obviously very important with leeks that are wet and often contain grit.”
John Warnock’s new packaging lines are also fully automated, with integrated infeed conveyors and labellers, which again increases efficiency and reduces labour requirements, with electronic no-product-no-bag producing further cost savings.
The fresh produce industry is characterised by successful growers like Allpress Farms and J Warnock. And a low-cost, stainless steel flow-wrapper like the Carrera 500 PC can make a huge difference to their operations, allowing them to match the quality of their produce with first class packaging that helps them to sell their products, while operating reliably and efficiently in a very demanding environment.
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