Southern Salads Continuous Motion PackagingSouthern Salads, based in Kent in the UK has recently installed two Novus 350s to pack their Iceberg lettuce and other leaves. This installation is part of a major investment in their processing and packing facility.

Southern Salads is a hugely successful family run business. Starting life off in markets in London, CEO & founder Ray Boakes developed the business by supplying shredded lettuce to multinational high street restaurant chains and has continued to serve this market ever since.

Southern Salads is a long-standing Hayssen Flexible Systems’ customer who utilise several intermittentSandiacre TG 320 machines to pack their products. When they decided to move forward with continuous motion packing, it was a logical move to choose Hayssen Flexible Systems’ machinery. Their new Novus produce specification machines have been specifically designed to improve speeds, pack integrity and decrease maintenance and servicing costs against current machines.

The unique product stager device prevents product from getting into the end seals and the Novus’ Quali-seal jaws offer extended sealing times and increased pack seal integrity. The Novus’s independent bag squeezer reduces oxygen levels in the bag, while the gas flushing feature slows down bacterial growth, increasing the longevity of the product’s shelf life. “Hayssen Flexible Systems’ ability to supply machines with a guaranteed increase in output and seal integrity was a key decision making factor to help us better serve our customers,” says Andrew Boakes, Managing Director at Southern Salads.

Andrew Boakes explains further “Having experienced Hayssen Flexible Systems’ outstanding after sales service support for many years it was an easy decision to continue our relationship with them. Their technical team are always readily available to give support and advice which we highly value.”

 
SGL Co-Packing Novus VFFS

The new Novus 350 packing machine in situ at SGL Co-packing's clean room at one of its factories in Nelson, Lancashire, UK

SGL Co-packing Limited, the Nelson, Lancashire-based contract packer and contract manufacturer, reports that it has invested in new packaging equipment this year in response to customer demand – extending its ability to provide flexible, high-speed packing solutions. The company is a wholly owned subsidiary of The Keswick Enterprises Group – the UK-based supply chain services specialist.The investment includes a new Novus 350 continuous motion vertical form fill and seal packing machine from Hayssen Flexible Systems. This robust, reliable and flexible unit may be adapted to create various pack styles – including quad pack, Doy and block bottom, as well as the standard pillow pack.

SGL Novus CloseUp

The new Novus 350 will extend SGL Co-packing's ability to provide flexible, high-speed packing solutions

Andrew Palmer, Chairman of SGL Co-packing, commented: “We are looking to build on our success as a leading UK co-packer by investing further in systems and equipment to support the development of customers’ products. The new Novus machine meets our requirements for high quality, flexibility and cost-effective operation, and has already generated considerable interest from existing and prospective customers.”

For more information please see www.keswickenterprises.com or www.hayssen.com.
 

Fenmarc Produce ltd, based in Elm, Cambridgeshire, has been growing, preparing, packing and supplying vegetables to major multiples and wholesale markets for over 40 years. Starting off as a farming co-operative, established by growers, Fenmarc offers superior customer service using its vast knowledge of farming and food processing. Today Fenmarc is one of the leading fresh produce suppliers in the UK, employing over 400 colleagues.

Fenmarc has various baggers on site, including one of Hayssen Flexible Systems’ intermittent VFFS machines.

After attending Hayssen Flexible Systems’ imPACKED show, Fenmarc decided to purchase the Novus 350 exhibition machine. One of the many advantages of purchasing the Novus was that Fenmarc could purchase the machine on a very short delivery time. The Novus continuous motion packaging machine allows Fenmarc to produce packs at an increased output.

“Our existing Sandiacre intermittent machine has always been extremely reliable, but we were interested to see what improvements a new machine could offer,” explains Gary Nassau, Site Engineering Leader at Fenmarc. “After seeing demonstrations of the Novus’ capabilities at the imPACKED show in Nottingham, we decided to purchase the machine. The customer service and spares delivery from Hayssen Flexible Systems has always been superb and was another key factor in our decision.”

The Novus 350 VFFS packaging machine offers benefits, such as high speed capabilities, packing bags of up to 200 bags per minute, dependent on film and product. The Novus’ modular assemblies and user interface facilitate easy and quick format changeovers, allowing customers the flexibility to switch between bag styles and sizes with ease. For more information, regarding the Sandiacre Novus continuous motion packaging machine, please contact  sales@hayssen.com or check out some videos of the Novus in action on Hayssen’s  YouTube channel.

 

McEntire Produce, headquartered in Columbia, SC, is a fresh produce processor, repacker and wholesaler serving the Southeast for over 70 years. McEntire Produce is always looking for ways to improve efficiency and increase speeds in their produce packaging lines to meet customer demand. After initially agreeing to be a beta testing production site for HayssenSandiacre’s Novus Produce vertical form fill seal machine, McEntire Produce has purchased the continuous motion machine for its exceptional performance.   McEntire Produce has been impressed with the Novus Produce Machine since shortly after receiving the machine. Tom Ribken, HayssenSandiacre Sales Executive, represents the southeast U.S. and worked closely with McEntire Produce from install of beta machine to purchase. Ribken comments on McEntire Produce’s decision to go with the Novus, “The wow factor happened when this bagger consistently met speeds of 55 bpm for a compressed 5lb package of shredded lettuce.  The existing baggers in the plant are not capable of attaining the Novus bpm’s while consistently maintaining package integrity.”

McEntire’s Maintenance Manager comments, “We were looking for ways to increase speeds while maintaining clean end seals and low leaker rates. The Novus has delivered on all counts. Our business is continuing to grow and we are looking to add a second Novus combined with an Ishida scale in the near future.”

Along with impressive speeds, the Novus Produce machine also features an independently timed stager which prevents product from contaminating end seals resulting in package leaks.  Other features include independently timed bag squeezer to compress bag size, orbital style knife and Quali-seal jaws.  HayssenSandiacre has worked with national produce companies for many years and helped to pioneer pre-washed, packaged bags of salads/lettuce.  The new Novus Produce machine joins the Ultima family of machines to further extend HayssenSandiacre’s product line which are well-suited for fresh cut produce applications.

 

Lion Dairy & Drinks has just recently  installed a Novus 350 in their cheese packaging facility in Allansford, Victoria, Australia. This customized form fill seal bagger forms a Quad stand-up packagewith re-closeable zipper using continuous motion sealing technology.  Lion’s dairy portfolio includes market leading brands across the milk, juice, cheese, dairy products and soy categories, and four out of the top 25 grocery brands in Australia. Lion’s cheese brands include Coon, Cracker Barrel and Millel, sold in retail supermarkets.

The Novus 350 Quad bagger is key for packaging two different product offerings from Lion; one is a mozzarella & cheddar mix with re-closeable zipper in 250g and 500g stand-up quad packages.  Lion also packages single serve cheese for pizza toppings in a 125g package. The Quad stand-up package will differentiate their brands among store competition. Michael Murphy,  Engineering Leader at Lion’s facility, comments on their choice of the Novus VFFS system, “We have a long-standing relationship with HayssenSandiacre and had full confidence in their ability to deliver this not-so-simple application for our new cheese product introductions.”

This site had also purchased a Hayssen Servo Ultima vffs with combination scale for their bulk shred line and (2) RT horizontal form fill seal wrappers with reclose from HayssenSandiacre in recent years. This facility has multiple RT hffs systems in operation for over 20 years.

Gordon Wood, Australian Sales Manager for HayssenSandiacre adds, “We have been proud to support Lion with their previous projects in packaging cheese on our horizontal RT systems and I am excited for the growth of their brands.  Our offerings for VFFS mean that we can provide Lion with future-proof systems that package a wide range, from single serve cheese packs to large format foodservice bags.”

 

Giant Snacks of Wahpeton, North Dakota prides itself in offering  the largest (hence the name ‘Giant Snacks’) sunflower seeds for its customer base. Specializing in roasting and packaging high-quality in-shell sunflower  seeds, in-shell pumpkin seeds, and corn snacks, Giant Snacks offers multiple  flavors including Dill, Salt & Pepper, Bacon Ranch and Kettle Roast (a  lower sodium sweet flavor). Sunflower seeds are sold to consumers in 3-oz,  5-oz, 5.75-oz, 9-oz and 12-oz with easy resealable pour spout bag sizes.

To process and package more than 3.5 million pounds of sunflower seeds each year, Giant Snacks  operates two twelve-hour shifts, five days a week. Working with  HayssenSandiacre, Giant Snacks recently purchased a Novus VFFS bagger to expand  their packaging line. Giant Snacks previously purchased Ultima VFFS systems for their  products and are happy with the performance and durability. This led them to  look at HayssenSandiacre’s newest model, the Novus continuous motion bagger to  increase throughput speeds.
“Quality assurance  is important throughout the production process to make sure shells are not  broken or dirty, are firm and do not have a limp texture. All packages are  nitrogen flushed to assure shelf freshness,” says Al Engstrom, Giant Snacks plant manager. Just as quality is important in selecting and packaging the  seeds, fully automating its five integrated packaging lines was a priority to  increase productivity.

Sunflower seeds are fed into Yamato series scales as part of the  HayssenSandiacre Ultima ST form-fill-seal machines or the Novus continuous motion form-fill-seal. After  sealing, the package runs through a metal detector, followed by robotic pick  and place case packer. The cases are bar coded with the product type, size,  date code, time packed and who packed it. Cases are then sealed and distributed all over the U.S.

 HayssenSandiacre is proud to be part of Giant Snacks’ operations as  they continue to grow. The exceptional taste of Giant sunflower seeds goes  back to 1958, when Bob Schuler began selecting the best-tasting sunflowers for  his customers. Dedication to quality is still top-priority and Giant Snacks  remains a family-owned company.

 

Pinguin Foods Develops New Pillow Pack with Zip for IQF Peas: Packaged on Novus VFFS with ITZ

Pinguin Foods is now producing their new pillow pack with zip using HayssenSandiacre’s VFFS Novus

Pinguin Foods is a producer of IQF vegetables, with thirteen production sites, primarily situated throughout Europe with the UK site being based in King’s Lynn, Norfolk. Pinguin’s frozen vegetables can be found in many of the leading supermarkets in the UK.

The pillow pack with zip is a more consumer friendly way of storing IQF peas, as the pack can be opened and closed easier than the standard pillow pack. For bigger bags of IQF peas, this helps to ensure that there is less wastage when storing in the freezer.

HayssenSandiacre was able to offer an integrated transverse zip applicator on their Novus machine, which could very easily switch between the pillow pack and pillow pack with zip option. Despite the complexity of the pillow pack with zip, the speed of the pillow pack with zip is similar to that of the standard pillow pack.
Paul Spurrell, Engineering Manager at Pinguin Foods in the UK described HayssenSandiacre as being a great partner in the development of this new pack format.

“HayssenSandiacre have been fantastic to work with right through the order process from zip selection to the site support for our customer trials. One major benefit is that our overall line speed has not been compromised with the introduction of the zip, as we have been able to maintain our bag maker speed.”

Pinguin Foods is currently packing their bags of IQF peas of weights ranging from 750g up to 1.81kg on the Novus 350TZA (Transverse zip applicator) continuous motion packaging machine.

 
British Bakels

British Bakels

HayssenSandiacre’s twin tube intermittent packaging machine produces readymade piping bags, using its specially modified jaws, set at 45 degrees. The Twin machine doubles the production output, whilst reducing floor space compared to two single machines. Each side of the Twin machine can work independently, allowing total flexibility on pack sizes and weights.

Individual dosing pumps mounted on each side of the bag maker, feed the required dose directly into the bags via the forming sets. Finished bags are discharged via two variable speed conveyors. Controls for both the printers and bag maker are conveniently located in one area, allowing for more efficient usage.

Twin TG250

Twin TG250

British Bakels Ltd is an existing customer of HayssenSandiacre and already owns a TG250L purchased in 2004, which is currently being used to pack their range of cake mix products.

Simon Dawson, Engineering Team Leader at British Bakels Ltd, explains British Bakels Ltd’s reasons for choosing HayssenSandiacre, “We were very impressed with HayssenSandiacre’s TG250LFT, particularly its capabilities to produce our ready-made piping bag. This machine was ideal for packing our product. We have worked with HayssenSandiacre previously and we felt confident that they would manufacture a machine to suit all our requirements and we have not been let down.”

 

Nature's Choice Foods

Nature’s Choice Products in Johannesburg, South Africa has invested in a HayssenSandiacre Novus 350 machine for their frozen vegetables factory.

“Having worked with HayssenSandiacre since 2006 and currently utilising 4 vertical Form Fill Seal bag makers from HayssenSandiacre, it was a natural decision for Nature’s Choice to choose the Novus to meet their expanding business needs,” Lloyd Mitchell CEO of Nature’s Choice commented.

“We have been looking to increase our packaging capacity for a number of months. When HayssenSandiacre informed us that they had a fully stainless steel Novus, high speed machine at the ProPak Africa show in Johannesburg in early March 2013, it helped us to make a quick decision to take the opportunity and buy the machine. The show finished on the Friday and by Sunday the machine was in our factory producing filled packs.”

Nature’s Choice Products are one of Southern Africa’s largest growers, processors and packers of IQF Vegetables and French Fries.

 
Country Crest Invests in HayssenSandiacre’s Novus 350 VFFS

Country Crest, based in Lusk in Ireland, has just purchased their 6th HayssenSandiacre machine. Country Crest decided to purchase another continuous motion packaging machine from HayssenSandiacre to help increase productivity in their potato packaging process.  The decision was made easy by the fact that HayssenSandiacre could offer a short lead time and high flexibility on machine options.

Steve Sheridan Maintenance Engineer at Country Crest explains: “We needed to replace one of our existing packaging machines and have had a great experience using HayssenSandiacre machines in the past that it was an easy decision to make. We needed the packaging machine quickly to try and meet our high consumer demand and we were delighted when HayssenSandiacre said that they could meet this requirement”

Country Crest has bought the Novus 350 to produce both pillow packs and block bottom bags using laminate film as part of an upcoming project.

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