Ishida Europe logo

Ishida experience helps dry fruit packer overcome seasonality challenges

31/12/2002

Plasto packs dried tree-fruit, including dates, prunes and figs, for many leading dried fruit brands. Not only are different fruit in demand at different times of the year, but the same fruit may need to be presented in different pack types, depending on the season.

Plasto had three linear twin weighers working mainly on one type of fruit, packed in a special format for one particular customer, a process that was quite labour-intensive.

The company decided to replace this part of its operation with something more flexible in terms of products packed, giving greater year-round usefulness. For example, it was hoped that the new system could also handle large bags of dried fruit, which are generally in demand during the Christmas season.

It was also hoped that a lower level of staffing would be needed, since labour was in short supply in other parts of the packing plant.

Ishida’s expertise in distribution systems

Plasto consulted Ishida Europe, because of the company’s expertise in distribution systems. “We could see that the distribution system would be key”, says Brett Abbott, Operations Director of Plasto’s plant at Beckton, London. “You can have the fastest weighing machine in the world, but it’s of little use if the product can’t be packed quickly enough.”

“Just taking a walk round the Ishida factory in Birmingham convinced me that they had the experience and resources we needed. I just didn’t feel we could get the same level of service from anyone else.”

The system which Ishida installed was based around a 14-head weigher of Ishida’s latest M series. The multihead weigher has rigidised, embossed surfaces to ensure the sticky dried fruit keeps moving.

Now handling different packs as the season demands

The Ishida multihead weigher has in effect replaced six outdated linear weighers. In order for this new model to be able still to feed the three existing packing machines, Ishida devised a special flexible distribution system. This comprises a three-position swing chute that moves between the three weighing machines, feeding each in turn.

In addition, when bags of fruit are required instead, the chute is fixed in its central position and a bagmaker moved into place beneath it. The interface between the multihead weigher and the bagmaker is achieved by simply switching programs on the Ishida Remote Control Unit.

Labour costs cut by 60%

The new system was achieving specified production levels within a week of installation, and is on target to achieve payback within 18 months.

It has also reduced by five the number of workers needed on this line. The much needed extra workers were re-deployed elsewhere in Plasto’s operation.

"This is not a high margin business, so any new weighing equipment has to make its mark quickly", says Brett Abbott.

"The fact that the Ishida weighing machine is so simple to use is an added factor. The RCU is particularly operator friendly, and most of our staff can handle it for operations such as cleaning, changeovers and routine running."