Froneri, a global powerhouse in ice cream, and the owner of New Zealand’s beloved Tip Top brand, approached us as they implemented their worldwide ‘bigger, better, faster’ strategy. The challenge was simple: ‘speed things up and save us time and money without compromising the product’.
The customer’s existing machines in their Mount Wellington, Auckland factory could not be adapted to manage the increased workload and we worked with the Head of Operations and Plant Manager Martin Utschig to devise a brand-new conveying solution.
A vital factor was the need to ‘lock’ the tapered tubs of ice cream together into a robust stack (three high by three wide) ready for shrink wrapping and palletizing.
Because of the enormous volumes at play (currently 4,000,000 tubs and counting) we created the all-important rotation helix section as a real-life ‘proof of concept’ trial.
One in three ice cream tubs must be rotated through a gravity propelled twist chute to obtain the all-important ‘lock’ when 3 are stacked. Once we had this section running perfectly to the customer’s satisfaction we pressed ahead and produced a unique three lane conveyor which separates a single stream of tubs into three evenly distributed lanes. As always, we needed all the machinery to be gentle on the tubs, low maintenance and reliable.
Dynamic laning removes any stop/start issues with shock-loading meaning that the lids never pop off during the process.
Food hygiene is obviously paramount and the whole system is designed to be fully washable.
Once the middle lane has been rotated, the tubs are collated, and a servo-controlled stacker is used to stack the rows three high. The next module of the RML system performs the shrink-wrapping and these are then ready for the pallets.
Installed in late 2020, the wrapper and conveyor is showing no signs of wear and tear and we are looking forward to a long and fruitful business relationship.
Our integrated, advanced operation ensures the best quality cream cheese is produced consistently.
It was an opportunity to increase the packing line automation, with labour savings offsetting the capital costs.
RML worked with us to understand our requirements and designed a solution to suit our needs. RML delivered an automated system to service two moulding machines producing the Gallagher Ring Top Posts.
We set RML a challenge, design and build a new butter packing machine for a challenging application. RML produced a smart and effective solution that exceeded our expectations.
Ongoing service and support is important to us. RML knew this and I am pleased to say we are not disappointed. I have and will continue to recommend RML to others in our industry based on our experience
We have found RML to be a professional automation solutions provider dedicated to developing, building and maintaining our sophisticated equipment. Their open and honest approach has resulted in very positive outcomes for us.
From the first day we sat down with the RML team, through to today, we’ve been so impressed by the level of service and quality of machinery that they have built for us.
Of all of the types of packers that we have on site (past and present) the RML packers have proven to be the most reliable, and easiest to maintain.
The design process went very smoothly, start up and commissioning went better than we anticipated. We have found the RML team to be professional, proactive and very responsive to questions and quick to resolve any problems for us.
IF YOU HAVE A PRODUCTION CHALLENGE,
WE’D LOVE TO SOLVE IT.
6 Chafer Place,
Burbush, Hamilton 3200
13-17 Hillwin St,
Reservoir VIC 3073
