Client: Leading Chocolate Manufacturer, Poland
Industry: Food Manufacturing
Project Scope: Refurbishment and modernisation of a 1970s VFFS (Vertical Form Fill Seal) machine
Solution Provider: A D Engineering Packaging & Automation
Refurbishing and modernising older VFFS packaging machines provides significant advantages, including cost savings, improved efficiency, and extended operational lifespan. Instead of investing in a completely new system, companies can retain their existing infrastructure while benefiting from cutting-edge automation, enhanced food safety, and increased productivity. A D Engineering specialises in transforming outdated VFFS machines into modern solutions utilising the latest technologies on the market, helping clients maximise their production potential.
The client was operating a 1970s hydraulic VFFS machine for chocolate packaging, which was suffering from inefficiencies and safety concerns:
• Manual Adjustments: The fully mechanical machine required constant manual adjustments to set bag size and speed, causing delays and inconsistencies.
• Extended Warm-Up Time: The machine took an hour to warm up before cycling, leading to significant downtime.
• Oil Contamination Risk: The old system operated with mechanisms submerged in oil, an unsafe practice for food production environments.
• Obsolete Mechanisms & Controls: The machine’s mechanical and electrical components were outdated, making repairs difficult and efficiency suboptimal.
• Limited Speed & Productivity: The slow operating speed placed excessive demand on other machines, increasing labour requirements.
A D Engineering provided a complete refurbishment and modernisation solution, transforming the obsolete VFFS machine into a state-of-the-art packaging system:
• Fully Automated System: Eliminated mechanical adjustments by integrating a digital touchscreen interface for setting bag size and speed, enabling effortless operation.
• Instant Startup: Removed the warm-up requirement, allowing immediate machine operation and eliminating downtime.
• Oil-Free Operation: Redesigned the mechanism to eliminate the need for oil, significantly improving food safety and compliance with industry standards.
• Complete Redesign: Overhauled both mechanical and electrical systems to optimise performance and reliability.
• Latest Allen-Bradley Safety System: Upgraded all electrics with an integrated safety system and modern display, ensuring full functionality and compliance.
• Modern Pneumatics: Replaced outdated pneumatic components with up-to-date standards, improving efficiency and longevity.
• Increased Speed & Productivity: Achieved higher packaging speeds, reducing the workload on other machines and lowering labour costs.
• Multi-Language Interface: Added language options to enhance usability for the diverse workforce.
• On-Site Commissioning: The A D Engineering team travelled to Poland to commission the machine, ensuring it was fully operational and met all client requirements.
• Reduced Downtime: Immediate machine startup improved operational efficiency.
• Enhanced Food Safety: Oil-free operation eliminated contamination risks.
• Simplified Operation: Digital controls reduced manual intervention and errors.
• Improved Productivity: Higher speeds reduced labour requirements and optimised workflow.
• Future-Proof Technology: Modern electrical and mechanical systems extended machine lifespan and reliability.
A D Engineering Packaging & Automation successfully transformed a 50-year-old VFFS machine into a high-performance, fully automated system.
This case highlights how even the oldest packaging machines can be modernised to meet contemporary standards, enhancing efficiency, safety, and productivity.
By also commissioning the machine on-site in Poland, A D Engineering ensured that the system operated flawlessly according to the client’s requirements.
Thinking of upgrading your VFFS machine? Contact A D Engineering Packaging & Automation to discover how we can modernise your equipment, regardless of age.
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