The Challenged Solution

Industries

Bakery, National Account, Retail

Products

Custom Equipment

Benefits

Labor Savings, Space Maximization, Throughput Process

Pacific Conveyor Systems Bakery System

Stepping up to the challenge in meeting production demand

The Client

A commercial bakery facility handling large volume contracts

The Situation

This large commercial bakery in Canada was started by one of Canada’s leading restaurants to handle all of their “always fresh” baking needs and quickly expanded to produce both sweet and savory items, eventually being sold to a large international food conglomerate. A U.S. division of the conglomerate had been awarded a contract to produce a filled bakery item by a national fast food chain requiring an extremely high production rate.

The Challenge

Pacific Conveyor Systems (PCS) had built a system during the pilot phase, which could fill 60-100 items per minute, but once sales went national, production would need to fill 1800 items per minute. The company solicited worldwide bids to fulfill the operational needs for this contract. To meet the production volume, PCS designed a system to fill 300 items per minute, which would require six systems to meet the demand. No other company felt it could meet the challenge of the required production rate and declined to bid.

The Solution

Budding SolutionSQWith its exceptional and experienced engineering team, the PCS system was designed and built to accomplish the following in one minute:

1. Divided and sorted 300 items into 15 lanes of 20 items.
2. Moved the lanes of items to a station where they were centered and filled.
3. Loaded the filled items into shipping trays.
4. Parallel to the above, a placer machine set trays onto an indexing conveyor which eventually moved them into a loading position.
5. Loaded trays were run through a detection machine to ensure fill volume was correct and no contaminants were present.

Six systems were built and installed and continue to meet the 1800 items per minute production rate. Not only did PCS meet the required demand, but saved on both machinery, flooring, and operator costs by building machines with a production rate that only required six machines, a number that no other company felt it could achieve.

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