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Case studies from Fox’s, Humdinger and Devonvale After-sales servicing | Meet the team
Meet the
team
With our vast suite of flexible packaging solutions, the ILAPAK team can satisfy every form, fill and seal packaging requirement of the food, medical device and wet wipe industries. Besides horizontal and vertical packaging machines, our portfolio includes systems for modified atmosphere applications, product handling solutions, counting and weighing systems and complete, fully automated lines. We have expanded year-on-year for the past seven years and now employ 30 permanent members of staff. Whether your query is technical, sales or service-related, we’d love to hear from you. Contact your packaging partner today to see how we can help.
Tony Dean, General Manager Having been with the company for six years, Tony ensures our operations and servicing departments are running smoothly and also manages a number of ILAPAK’s key accounts. T 07785 238312 E tdean@ilapak.com
Sales query? Contact...
Mark Wood, Product Manager for the vertical form/fill/seal range A recent addition to the ILAPAK team, Mark has worked in the food processing and packaging industry for over 16 years. T 07768 213926 E mwood@ilapak.com
Chris Gibson, Product Manager for the vertical form/fill/seal range
Tony McDonald, Sales Director With over 22 years of service at ILAPAK, Tony heads up our sales force, overseeing seven members of staff covering the length and breadth of the UK. T 07768 213918 E tmcdonald@ilapak.com
A new addition to ILAPAK, Chris brings 13 years of experience in food processing, weighing and packaging equipment. T 07391 405035 E cgibson@ilapak.com
Tony Bryant, Southern UK Sales Manager for the horizontal product range
Zygi Mikolaitis, Technical Manager
Servicing query? Contact… Tony joins us with a wealth of FMCG and retail compliance experience, having spent the past 18 years successfully heading up the UK sales and service division for an inspection system/metal detection firm. T 07880 384993 E tbryant@ilapak.com
Sham Rana, Product Manager for the Smart range Sham brings years of experience in high hygiene food and pharma applications in North America. Sham is currently helping craft bakers and confectioners grow their business. T 07551 153532 E srana@ilapak.com
Chris Gee, Northern Area Product Manager for the horizontal form/fill/seal range Supplying capital equipment to the food industry for over 23 years and part of the ILAPAK team for two years, Chris also handles high speed and high volume applications including the automation of feeding systems. T 07768 213915 E cgee@ilapak.com
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A former service engineer who’s been with ILAPAK for six years, Zygi’s technical knowledge is well-known throughout the industry. Zygi manages the field team, comprising nine service engineers. T 07918 565498 E zmikolaitis@ilapak.com
Sukhi Panesar, After-Market Team Leader Recently promoted to After-Market Team Leader, Sukhi acts as the link between ILAPAK’s spare parts and service divisions. T 020 8797 2027 E spanesar@ilapak.com
Samantha Bruce, Service Administrator As Zygi’s organisational support, Samantha’s role is customer-facing, being the first point of contact for our clients whenever they have a servicing request. T 020 8797 2010 E sbruce@ilapak.com
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Case study: Humdinger Ltd Machine: Vegatronic 6000 bagger
A humdinger of a bagger In brief UK bagged fruit and nut snack manufacturer Humdinger Ltd invested in two Vegatronic 6000 baggers from ILAPAK as part of a company-wide drive to
Why choose the Vegatronic 6000 Continuous Film Motion (CFM) vertical bagger?
achieve operational excellence. The bagger’s swift changeover capabilities and multi-format flexibility has seen line efficiency improve by 50%.
Challenge
✓ Capable of pillow packs up to 200ppm, pillow bags at 120ppm and quad bags at 80ppm, running several different films including pre-applied labels
Humdinger produces snacks for retailer own labels and licensed brands
✓ Equipped with printer and labeller
(including Marmite, Branston and Peperami) alongside its own branded range. This varied portfolio calls for a flexible packaging operation – bags
✓ Unique jaw profile guarantees seal integrity at high speeds
range from 80-500g and can be either quad or pillow in style. While the
✓ Hermeticity guaranteed at -0,5 bar
company’s existing baggers could handle these variations, individually they didn’t have the format flexibility required.
✓ Open frame design offers unrivalled accessibility ✓ Ultra-hygienic construction enables full washdown capability
Solution Humdinger could immediately see the potential offered by the Vegatronic
✓ Fast tool-less format changeover
6000. The continuous motion bagger can run off the full gamut of bag styles, including pillow, block bottom, quad and doy-style packs, and the ease with which it can switch between these was one of the deciding factors for Humdinger. Capable of up to 200ppm on pillow packs, the Vegatronic 6000 is engineered for high speed operation; the machine’s compact design means there is less distance for the product to travel, whilst the electrical control platform and unique jaw profile guarantee seal integrity. It can produce quad packs in-line or on the tube.
Benefits The Vegatronic 6000’s speed capabilities were tested in extensive trials which proved it could comfortably meet the customer’s speed criteria. The in-line configuration specified for this project allows higher speed operation and delivers aesthetic benefits due to reduced friction in the tube and better control over the film. Fed by an existing multihead weigher, the Vegatronic 6000 is specified to produce quad bags at speeds of up to 80
Paul Ramsey – Operations Director, Humdinger
per minute and pillow packs up to 120ppm. Line efficiency has improved by 50%.
+44 (0)20 8797 2000
“We asked various equipment manufacturers to tender against our URS (User Requirement Specification). ILAPAK were very thorough in understanding what was required and asked for clarity to ensure what they were proposing worked fully. The project set-up was very good, with excellent attention to detail during the trials. As a result, we have increased our format flexibility by investing in a machine that can produce more than one pack style, achieving a significant improvement in performance.”
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Case study: Fox’s Machine: DSA Eagle flow wrapper
Helping Fox’s out of a CRUNCH situation Why choose the DSA Eagle? ✓ Max 1,000 ppm ✓ Robust hygienic design ✓ Smart 14” full colour screen for ease of use ✓ Statistical information at your fingertips
In brief When one of Fox’s high speed flow wrappers failed, leaving the biscuit manufacturer with a financially crippling downtime situation on its Rocky bar line, ILAPAK came to the rescue. One of the few flexible packaging equipment manufacturers with the capabilities to supply a 1,000 biscuits per minute line, ILAPAK reacted quickly when Fox’s wanted to purchase an exhibition model Delta Systems & Automation (DSA) Eagle flow wrapper.
Challenge Fox’s Rocky brand is a UK household name. To keep supermarket shelves stocked, the manufacturer has four lines operating 24/7 at speeds of 600 bars per minute at its factory in Kirkham, Lancashire. With some of the equipment on these lines nearing the end of its lifespan, Fox’s visited Interpack to research upgrade options. ILAPAK’s US-built DSA Eagle flow wrapper was on display at the show and Fox’s was impressed with its rare ability to wrap biscuit bars at speeds in excess of 1,000ppm. But before Fox’s had a chance to resume discussions with ILAPAK, one of its high speed flow wrappers broke down and due to obsolescence, couldn’t be fixed. With throughput down by 40%, Fox’s Chief Engineer Paul Nolan contacted ILAPAK to see if Fox’s could buy the model he had seen at Interpack. At the time, the flow wrapper was being shipped back across the Atlantic, but arrangements were made to return it to the UK as soon as possible and transport it to Kirkham.
+44 (0)20 8797 2000
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Solution Installing it on the line was far from straightforward, as it had to be interfaced with upstream and downstream equipment that was operating on different and older control platforms. “A lot of equipment suppliers shy away from the challenge of integrating a new machine into an existing line where the control systems in use are old, as it isn’t easy to get machines to communicate with one another when, essentially, they are talking in different languages,” says Chris Gee, Sales Manager HFFS at ILAPAK. “In this case, it was a lot of work to get the flow wrapper to interface with the upstream accumulation tower and feeding system and the downstream over-wrapper.” However, it wasn’t long before the line was back up and running with the new flow wrapper in place.
Benefits Engineered for 24/7 production environments, the DSA Eagle incorporates features such as automatic splicing and expanded touchscreen diagnostics for efficiency excellence. Heavy duty construction and the design of its feeding system are also key to the flow wrapper’s exceptional performance at high speeds. “There is a lot of vibration when running at these kinds of speeds,” explains Chris. “The Eagle is based on a very heavy duty mechanical platform and 12.5mm thick plate frame construction. This ensures stability and smooth operation of the jaws at very high speeds.” The Eagle also deploys advanced sensor technology to perform a profile check of each biscuit just before it enters the flow wrapper, as uniformity is imperative at these high speeds. “The system checks length, height and width of each bar and any products that fall outside of the programmed parameters will be rejected before they enter the flow wrapper and cause jams or blockages,” says Chris. Now enjoying the ability to wrap 1,000 biscuits per minute, Fox’s is looking at upgrading its other flow wrappers to DSA Eagle systems, as well as future-proofing the rest of its plant – projects in which it says ILAPAK will be heavily involved.
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“I value ILAPAK’s openness, their readiness to provide solutions and the partnership we have. It’s a rare combination and I don’t think we have that with any other equipment supplier. The pace at which they moved and their willingness to help us out was admirable.” Paul Nolan – Chief Engineer, Fox’s
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Case study: Devonvale Bakery Machine: Carrera 1000 flow wrapper
Baking it BIG Why choose the Carrera 1000? ✓ Perfect for mid-range bakery environments ✓ Maximum 250 ppm
In brief ILAPAK has supported Devonvale Bakery throughout its journey from start-up to multi-million pound business, specifying flow wrapping solutions that have enabled the cake and cereal bar producer to match capacity with demand. The latest investment has seen Devonvale more than double its line
✓ Robust, hygienic design ✓ All components commercially available
speed by making the step up from manual cutting and feeding to a seamless automated workflow with ILAPAK’s modular Carrera 1000.
✓ Full colour operator screen for ease of use
Challenge “Our packaging operation is far more efficient; the quality and appearance of the packaged product is much improved and our staff are benefitting from a more pleasant and less stressful working environment. We now have one flow wrapper doing a job that used to require two machines, and it is doing it far more efficiently.” Keith Upham – Managing Director, Devonvale Bakery
Devonvale purchased its first ILAPAK flow wrapper in 2004 – the entry level Carrera 500 – to wrap flapjacks, cakes and other traybakes into individual portions. It purchased its second in 2012, a Smart machine which doubled capacity at the East Devon bakery. Since then, Devonvale has gone from strength to strength, building a nationwide presence with wholesale distributors supplying vending companies, retailers and food service, as well as producing for other companies. Whilst the two flow wrappers were mechanically capable of up to 60ppm, Devonvale was unable to reach these speeds due to limitations imposed by the manual elements of the process, which also brought the risk of individual portions getting caught in the infeed and causing downtime.
Solution Following further growth, Devonvale made the decision to fully automate its packaging operation in 2017. ILAPAK managed a turnkey project to install a packaging line incorporating cutting, flow wrapping, labelling and coding, with the Carrera 1000 at its heart. The machine’s excellent build quality, IP65-rated hygienic construction and modular design was ideal for this project.
Benefits Supplied with a high speed, twin jaw configuration, the Carrera 1000 has future-proofed Devonvale’s packaging operation up to speeds of 250ppm. A smart-belt infeed that automatically pitches the squares as they come off the removal station adds to the efficient operation of the flow wrapper. With the new line running at speeds of 100-150ppm, Devonvale is delighted with the transformation.
+44 (0)20 8797 2000
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With you every step of the way We support our customers throughout the operational lifetime of their ILAPAK equipment and beyond, with aftercare of the highest quality. Alongside our standard 12-month warranty, we offer an unrivalled range of services and spares to increase your uptime and help you get the very best from your machine for years to come. Our dedicated service team – comprising a technical manager, nine service engineers, two in-house workshop engineers, four sub-contracted engineers and two servicing support staff – is always on hand to answer any technical or support requests, while our spares team ensures that the £600,000 worth of stock held in our UK warehouse is readily available whenever our customers need it. In fact, our 250 most popular spare parts have a 99.8% availability.
What else makes our aftercare the best in the business? WARRANTY
SIZE CHANGE PARTS
Every ILAPAK machine comes with our standard one-year warranty. We also offer extended warranties on request.
As a company grows, its equipment must be able to handle increasing production levels and changing consumer demand. Our size change parts facilitate expansion, enabling your existing ILAPAK machine to flex and grow in line with your business.
SERVICE CONTRACTS Covering everything from quarterly service visits to spare parts and emergency call-outs, our comprehensive service contracts keep your machine in optimum condition, giving you peace of mind.
REBUILDS If you’re looking to refresh your machinery, either due to general wear and tear or because of a change to your production process, then our rebuild service is the answer. Our in-house workshop engineers can refurbish your equipment, giving it a new lease of life for another 10 years or more…
TECHNICAL SUPPORT Our UK technical support line is manned 24/7 to give you maximum uptime. Contact our team of fully qualified service engineers at any time of the day or night to resolve your technical issues. If a call-out is required, we’ll get an engineer out to you as fast as we can.
UPGRADES We offer control system upgrades on all our machines. If an electrical system becomes obsolete, we can replace it with the latest connected technology, allowing you to keep pace with the digital times.
SPARE PARTS Our spare parts service operates seven days a week and usually contains £600,000 worth of stock at any one time. With a 99.8% availability on our top 250 parts, we offer a same-day delivery of genuine ILAPAK spares – even at the weekend.
COMING SOON… IlaXcare
TRAINING Our industry-leading training is bespoke to each client. Whether to support a new machine, a new member of staff or a new application, our specialist engineers can deliver tailored training sessions at your own facility to ensure you get the best out of your ILAPAK equipment for years to come.
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The very latest in servicing technology enables our engineers to see exactly what you see, by remotely accessing connected glasses worn by the customer. With the capacity to cut servicing time and reduce call-outs, IlaXcare is set to revolutionise the way machinery is maintained.
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the
difference
We’ve been in business for almost 50 years, supplying more than 2,000 quality horizontal and vertical form, fill and seal bagging solutions to companies across the food, medical device and wet wipe industries. What makes ILAPAK your perfect partner in packaging?
Knowledge and experience
Our trusted team brings a wealth of experience to each project, ensuring our clients get the right equipment with the right specifications, first time and every time. Our General Manager, Tony Dean, has over 30 years’ service in the food industry, and he’s not alone… • Sales Director Tony McDonald has celebrated 22 years with the company • Two of our service engineers have been with ILAPAK for over 29 years • Our four loyal sub-contractor engineers have a combined total of 80+ years’ service • Our dedicated back office support team comprises 12 long-serving members of staff • We’re also investing in the next generation of engineers, employing young recruits to ensure our continued success
Robust and reliable Our range of horizontal and vertical baggers, flow pack and flow wrappers deliver maximum production flexibility and efficiency at each performance level. Built to last, ILAPAK’s machines are robust, durable and reliable. But don’t just take our word for it… • 80% of our sales are from repeat customers • 75% of our machines are still in daily operational use 20 years after they were first installed “The Carrera 1000 does exactly what we wanted it do and has done from day one.” Keith Upham – Managing Director, Devonvale Bakery
Spares and service We’re not just a machinery supplier; we’re your one-stop-shop for parts and service, supplying genuine ILAPAK spares at competitive prices and offering an unrivalled aftercare service… • 99.8% availability on our top 250 spare parts • £600,000 stock held in our UK warehouse • No increase in our standard engineer rates for four years • 24/7 technical support • Same-day spares delivery, even at weekends
Bakery
Biscuits
Chocolate & Confectionery
Coffee & Tea
Dairy
Fish & Seafood
IQF
Meat & Poultry
Pet Food
Pharma & Medical
Pizza & Tortillas
Produce
Snacks
Wet Wipes
+44 (0)20 8797 2000
www.ilapak.co.uk
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