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Vf/f/s system invigorates packaging operations

Tortilla chip maker vanquishes material waste, while pumping up output and product shelf life.

LIFE-ENHANCING. Nitrogen gas-flushed metallized PP bags have increased average tortilla chip shelf life to 180 days.
LIFE-ENHANCING. Nitrogen gas-flushed metallized PP bags have increased average tortilla chip shelf life to 180 days.

Sourcing high-quality, locally grown corn, Abuelita Mexican Foods, Manassas Park, VA, specializes in the production of hand-crafted tortillas and tortilla chips containing no trans-fats or artificial ingredients. The company’s primary markets traditionally have been institutional foods and some specialty stores. For the tortilla chips, shelf life ranged from 55 to 75 days.

Originally the tortilla chip products were being packaged in preformed paper bags, using company-designed semi-automatic packaging operations. Five to seven Abuelita team members were assigned to the filling, sealing, check weighing, and case packing operations. The pre-made bags were difficult to fill accurately and to seal. Typically, every four out of ten bags were rejected because of poor seals or under- or over-weights. Scrapping four out of ten bags added 40% to the company’s packaging materials costs, and 6%-8% of product was wasted in the repackaging procedures.

As a result, Abuelita’s tortilla chip processing operations had to be throttled back nearly 50% from optimum throughput to accommodate the weakest link in the production chain--packaging. Total output of the two semi-automatic packaging lines averaged 1200-1300 pounds of bagged product per hour.

Ramping up for retail
Abuelita had ambitions to expand into larger retail markets and had received some inquiries from such markets. The company realized that, in order to tap into these new opportunities, some packaging systems upgrades would be needed to help propel the expansion and improve overall packaging efficiencies. In addition, the company needed to extend packaged product shelf life in order to appeal to grocery store chains and big box stores.

Abuelita’s VP of Operations Eugene Suarez, Jr., notes, “Bringing in high-speed vertical form-fill-seal machines and switching from preformed paper bags to a range of film bags was a scary proposition. While it opened the door to opportunities for expansion into the retail food market, it also presented challenges.”

Suarez knew that successful installation of new, state-of-the-art packaging machinery had to be well thought out and well executed. And the equipment selected would have to be rugged and easy to operate, maintain, and changeover. He attended Pack Expo and made contacts with several potential packaging machinery manufacturers. After some searching, Suarez found Abuelita’s packaging partner—Matrix Packaging Machinery, a Pro Mach company. The model of choice was the Matrix Elete vertical form-fill-seal system. The stainless steel frame equipment features automatic film tracking and optional printer/labeler add-ons. The system incorporates Allen Bradley MicroLogix, touch-screen operation, and it can perform temperature-controlled edge or center back seals.

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