Project Background: The Urgent Need for Upgrading Ketchup Packaging in Pakistan
In January 2024, a large food packaging company in Pakistan faced dual challenges of capacity expansion and packaging automation upgrade. With the surge in demand for convenient food among local consumers, their boxed tomato sauce products need to be paired with plastic spoons to enhance the end-user experience. However, traditional manual spoon sticking has low efficiency (about 2000 pieces/hour), poor attachment accuracy (easy to fall off and tilt), and continuously rising labor costs, which seriously restricts the overall efficiency of the production line.Customer Core Pain Points and Requirement Breakdown
1. Efficiency Bottleneck: The existing production line needs to meet the output of 100000 boxes of tomato sauce per shift, and the manual spoon sticking speed is only 25% of the demand, which cannot match the front-end filling capacity;
2. Accuracy Requirements: The spoon should be accurately attached to the designated area of the packaging box (with an error of ≤ 1mm) to avoid falling off or covering product information during transportation;
3. Compatibility Requirements: Compatible with customers' existing 3 different specifications of tomato sauce packaging boxes (length 60-100mm), and supports quick changeover.
Solution: High Speed Fully Automatic Spoon Sticking Machine
Based on customer needs, we recommend the SS-6000 high-speed spoon pasting machine and provide customized design solutions:
Ultra High Speed Operation: using servo drive system and precision robotic arm for collaborative operation, the actual operating speed reaches 6050/hour, exceeding customer expectations.
Food grade hygiene standards: The contact parts of the equipment are made of 304 stainless steel and support CIP online cleaning.
Intelligent Adaptive System: automatically corrects the position of the spoon through a visual detection device, ensuring a paste accuracy of ± 0.5mm and adapting to different box types and spoon sizes.
Seamless Integration: seamlessly integrated with the customer's existing filling line, installation and debugging can be completed in just 12 hours without the need for production stoppage.
Project achievements: Efficiency increased by 300%, cost reduced by 40%
Efficiency Leap: The spoon sticking speed has increased from 2000/hour to 6000/hour, meeting the customer's single shift production capacity requirements, and the overall efficiency of the production line has increased by 28%;
Cost Optimization: Replacing 6 manual workers, saving approximately $120000 in labor costs annually, and the equipment investment payback period is only 8 months;
Quality Improvement: The qualified rate of spoon sticking has increased from 85% for manual labor to 99.95%, and the customer terminal complaint rate has decreased by 90%;
Brand Value Added: Through automation upgrades, customer tomato sauce products have expanded their market share by 12% in the local market.
Customer Production Director evaluation: "Union Machinery's food machinery equipment not only solves our efficiency problems, but also becomes our core partner for capacity expansion through stable performance and professional services. ”
Why Choose Union Machinery?
· Expert Team: End-to-end engineering support from design to commissioning.· Global Expertise: 11+ years in food machinery, serving 50+ countries.
· Certifications: ISO9001 and CE compliant.
· Custom Solutions: Full-service support, including plant layout optimization.
· Support: 24/7 technical assistance, spare parts availability, 1-year warranty.
Take action now and start your productivity revolution!
This case is typically applicable to the food packaging industry that requires attachments such as tomato sauce, yogurt, jelly cups, etc. If you are facing the following problems:
Manual pasting has low efficiency and high cost
Strict packaging standardization requirements
Urgently need to increase production capacity to cope with export orders
Welcome to contact our engineering team for free production line evaluation and customized solutions!
Union Machinery， A global leader in food packaging, committed to enhancing customer competitiveness through innovative machinery. Complete export certification and 100% on-time project delivery rate.
Union Machinery——Make each product become your quality endorsement!
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