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New bagger brings sweet rewards

Constant breakdowns and an increase in production prompt Windy Acres to invest in a new vf/f/s machine.

Pw 7196 Windy 63

Packaging operations at Windy Acres in Wilmington, OH, have come a long way since Edward and Maxine English hand-packed candy and nuts in their kitchen to sell at a local flea market 20 years ago. Today, the candy manufacturer stocks more than 250 items, and the couple’s original kitchen scale and sealer have been replaced by fully automated packaging machinery.

But recently, the company’s continuous-motion vertical form/fill/seal machine couldn’t keep up with the increase in demand. In addition to being too slow, the bagger overheated constantly, causing the machine to shut down for 30 minutes at a time, as many as six times a day. Product waste was another issue. When candy and nuts were fed into the scales, some of the product would fall underneath the vibrating feeders. "If we were running mini bubblegum balls, we would get three to five pounds underneath the feeders that didn’t even make it to the scales," says Windy Acres business manager Jason English.

But that wasn’t all. Windy Acres’ main package size is a 10-oz pillow bag that measures 6 in. wide and 9 in. long. The company recently started running 2.5- and 5-lb pillow bags that measure 8 in. wide; however, the weighing system was unable to handle the increase in product for the bulk bags. "We couldn’t do a double dump for the bulk bags because the weighing system only had eight scales," explains English. A double dump slows the machine down to make the larger bag. "Also, the system wasn’t accurate, so we were giving away on average six grams of product," he adds.

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