INTEGRATED ISHIDA SOLUTION BRINGS SPEED, EFFICIENCY AND QUALITY BENEFITS FOR SNACKS MANUFACTURER
The installation of three high-performance Ishida integrated Total Packaging Systems (iTPS) at leading German snack manufacturer WURZENER Nahrungsmittel GmbH has improved weighing speeds by around 75% and almost eliminated product giveaway, while delivering higher quality snacks bags with fewer rejects and less product and film waste. This has led to a fast payback on investment. The Ishida iTPS’s are part of three new packing lines for WURZENER’s range of extruded corn snacks, including the company’s top-selling peanut-flavoured Erdnussflips, onion rings and cheese puffs. The iTPS is a fully integrated snack food packing system which combines a multihead weigher from the high-performance CCW-RV series with the Ishida Inspira, the world's most efficient bagmaker specifically developed for snack foods. Both machines are seamlessly integrated and operated via a single control panel. “Snacks, especially our Erdnussflips, are top sellers at WURZENER,” explains managing director Stefan Kuhl, adding that the company has “excellent market prospects” when it comes to selling to top German retailers. Funnels guide the snacks to the gantry-mounted Ishida CCW-RV multihead weigher. Loadcells underneath the multihead’s dispersion tables allow for a consistent product flow to the radial feeder troughs. The vibrating troughs transfer the product to a set of 14 pool hoppers, which hold them for a short time before supplying them to another row of 14 weigh hoppers. As soon as a weigh hopper becomes empty and is available for its next filling process, a signal is sent to the corresponding pool hopper. The system's software then takes just a fraction of a second to calculate the three best weigh hopper combinations, check them again and select the combination that come closest to the required target weight. The Ishida multihead weighers can complete many more weighing cycles than WURZENER’s previous volumetric system. For a standard 150g bag, the company’s managing director Stefan Kuhl says the weighing speed has been increased from 60 to more than 100 weighments per minute. “The significant improvement in accuracy is also important to us,” he adds, explaining that overfilling has been dramatically cut from 7.5% to almost zero. The weighed snacks are transferred to the bagmaker via a high-speed parabolic chute with integrated throat metal detector. “This is another benefit of the new packing system,” comments Stefan Kuhl. WURZENER uses the Ishida iTPS in a three-shift mode. The company has calculated that its investment will pay for itself within 2.5 years. Stefan Kuhl says he chose Ishida because of the technology manufacturer's wealth of expertise and experience in the snacks market, as well as the way that the machines can be integrated. “While there are plenty of manufacturers of bagmakers and rather fewer suppliers of multihead weighers, it is only Ishida that offers both products as an integrated solution,” he points out.