Upgraded and Automated: New Food Product Filler Line Improves Speed and Quality

Background

A Central Wisconsin consumer packaged goods company faced production inefficiencies due to an outdated line designed in the 1950s with a singular motor drive. The existing filler line(s) for their uniquely packaged food product were hard to clean, unsafe, and costly to maintain.

Approach

Our Serial 1 Automation team collaborated with our client to solve their unique business challenges. Rather than force-fitting an off-the-shelf solution, we were able to develop a custom automation solution to modernize their equipment, addressing immediate challenges and setting a new standard for efficiency and quality in the food and beverage industry.

This involved improving line flexibility, weight adjustments, product handling, packaging, and air material flow. Wisconsin-based Foth members and partners executed the installation, ensuring local expertise. 

Results

This first-of-a-kind custom automation solution led to remarkable improvements. Our client experienced enhanced seals through heater control, reduced sanitization time, improved safety standards, and increased the units-per-minute production speed by 20%. Additionally, there were 10x fewer product defects compared to the historical line performance. The packaging quality was the best the company had seen, and our client expressed a desire to purchase additional machines. 

Improvements in production speed, safety, and product quality have profoundly impacted the company’s operations, allowing them to achieve new levels of success and competitiveness. 

Foth’s Serial 1 Automation process provides customized solutions that are practical and forward-thinking. By focusing on clients’ specific needs, Foth delivers results that exceed expectations and drive long-term success. The project is an example of how our commitment to excellence and innovation can transform production processes and create lasting value.