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Stonyfield opts for in-line tf/f/s

For four years, Stonyfield Farm filled its 4-oz YoBaby organic yogurts for babies and toddlers into injection-molded polypropylene cups, with six filled and lidded cups automatically unitized in a wraparound paperboard carton.

Pw 13065 Yobaby1

Thanks to robust sales, the Londonderry, NH-based organic yogurt maker is now making changes to both its packaging machinery and materials to meet increased demand.

"We needed additional capacity," explains John Daigle, vice president of operations for Stonyfield Farm. "Our cup filling equipment was only four years old, but its capacity was 25ꯠ cups per hour. To get to 35ꯠ an hour we would have had to put in another line and added three more operators. And then we would have still had to run those individually filled cups through cartoning equipment." Outsourcing the work to a contract packager, he says, would have been cost prohibitive.

A more attractive option, Daigle says, was to add an in-line thermoform/fill/seal machine that its Paris, France-based parent company Danone had used. "Danone had several of these machines and they liked them a lot." So Stonyfield removed the cup filling line and began production in April on a new Model 6D-24 tf/f/s unit from Arcil.

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