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Booming sales brings new processing & packaging

Inventure Foods satisfies demand for kettle-style potato chips with a new seasoning and packaging line designed to even out product flow and maximize efficiency.

Four baggers on the ground floor are fed by these weighers on a mezzanine level.
Four baggers on the ground floor are fed by these weighers on a mezzanine level.

Inventure Foods recently felt the pressure of kettle chip popularity at its plant in Goodyear, AZ. Already operating at 90% capacity, Inventure needed to ramp up production quickly and efficiently when sales of its Boulder Canyon brand natural kettle-style chips grew 30% as supermarket chains introduced the product nationally. “The growth of healhful, natural products generally and our line of Boulder Canyon Natural Foods snack chips specifically brought our Goodyear plant to a point of maximum capacity,” explains Brian Foster, senior vice president of operations at Inventure.


The company quickly responded by completely updating its 60,000 sq. ft. plant in 2011, adding six new kettle chip batch fryers and a state-of-the-art product handling, seasoning, and packaging line. “As a growing food company,” says Foster, “we must maintain flexibility in our operations to serve both evolving consumer eating patterns and unique customer needs. We would not be able to support future growth without an investment in our capacities.”


But efficient packaging of batch-fried potato chips proved more complex than simply installing new bagmakers. Unlike a steady flow of chips produced by a continuous fryer, kettle chip fryers deliver intermittent batches. And since seasoning applicators, weighers, and bag makers work most efficiently with a consistent supply of product, these “waves” of chips can cause inconsistent seasoning and poor packaging productivity.


Inventure Foods recognized the distribution, seasoning, and packaging challenges unique to their batch potato chip process—and the need for production flexibility to quickly respond to changing markets. “Unlike some other firms our size, we have a healthy presence in every snack food distribution channel,” explains Foster. With orders rushing in, Inventure had to boost production quickly without stopping existing operations. After investigating several options, Inventure Foods selected Heat and Control to provide a complete product distribution, seasoning, and packaging line that could be installed quickly and still meet Inventure’s long-term needs for product quality, reliability, flexibility, continued growth, and ongoing technical support.


Inventure’s new system was designed by Heat and Control to even out the product flow and maximize the run-time of all components for greater production efficiency. “The increased capacity the new line delivers enables us to be more flexible in scheduling production to meet demand and to balance our inventories in a more efficient manner to service our customers,” explains Foster.


Accumulation
Batches of chips first enter the system through a SwitchBack accumulation conveyor modified for in-line product transfer. As a buffer between processing and packaging, the SwitchBack evens the flow of chips, delivering a steady supply to the FastBack Revolution distribution conveyors and on-machine seasoning system. Gentle FastBack horizontal motion distribution conveyors are equipped with patented cylindrical Revolution gates direct-mounted to the conveyor pans.


The Revolution gates rotate to deliver precisely the exact amount of chips required by each seasoning applicator, weigher, and bagmaker, while allowing the main supply of chips to continue to downstream units. This proportional distribution assures a continuous and consistent flow of chips with no “starvation” and just the right amount of feed to each seasoning and packaging system.


The brain behind this proportional distribution system is a PLC from Rockwell. Sensors on each combination scale send data through an Ethernet connection to this PLC. Essentially it’s a message saying “send more chips” or “sufficient chips are present.” The PLC then communicates with a Sumitomo gear motor on the Revolution gate telling the gate to rotate to an open or closed position, thus sending more chips to that combination scale or sending chips to the downstream baggers.

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