Automated Snack Packaging Line Expansion

Background

When we partnered with a major consumer-packaged goods company to modify and expand their building to enhance the packaging line for a snack product, the primary objective was to increase production capacity — particularly their short stick packaging — in response to a recent spike in consumer demand.

The project involved expansion of the building, implementing a comprehensive packaging system to handle various stages of the process, including cutting, sorting, thermal processing, metal detection, carton filling, case packing, and palletizing. These operations were centralized at the client’s plant, which is the only plant that produces this snack product in large volumes. 

Approach

The new system significantly increased production volume, more than doubling the output of existing lines. The project integrated new sorters and a high-speed loading system that greatly improved the speed and efficiency of the packaging process. The project scope included architectural, structural, power, controls, process, mechanical, and construction management for the building and installation of the new systems. 

Our team’s contributions also included enhancing the control systems through comprehensive plant network and data collection. The new electrical design improved line control and status updates, leading to increased automation and better visualization of operations. This automation reduced manual labor, with visual inspection being the primary manual task. 

Results

The project faced multiple hurdles, including implementation of new technologies from multiple vendors, overcoming space constraints, and making multiple design changes to accommodate evolving project requirements.

But a partnership approach with our client allowed for greater flexibility and adaptability, which resulted in setting a new record for the line’s production, achieving a speed of 1,900 sticks per minute with potential for further efficiencies and improvements.