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Case packer provides 'phenomenal' uptime for biscotti baker

Nonni’s Foods installs a wraparound case packer for its boxed biscotti products, resulting in increased production and flexibility, and consistent product presentation.

Nonni’s packs eight- and 10-count cartons and tubs of its Italian-style biscotti dunking cookies in a range of flavors at its Ferndale, NY, facility.
Nonni’s packs eight- and 10-count cartons and tubs of its Italian-style biscotti dunking cookies in a range of flavors at its Ferndale, NY, facility.

Nonni’s Foods LLC, an independently owned, premium bakery based in Chicago, markets its Italian-style biscotti gourmet dunking cookies under the Nonni’s brand name, with distribution in all 50 states, as well as Mexico and Canada. Near the end of 2011, Nonni’s decided to upgrade the packaging line at its Ferndale, NY, facility to keep pace with increased production capabilities upstream for its individually wrapped biscotti products.


The upgrade focused on automating the case-packaging operations, with a goal to provide cost savings and line flexibility while eliminating backlog and ensuring consistent product presentation. Upon investigating the market for wraparound case packers, Nonni’s awarded Schneider Packaging Equipment the contract to build the new case packer, a model WP-35.


Specified in January 2012, the machine was installed at the Ferndale plant in May 2012.


Says Nonni’s plant engineer/maintenance manager Norm Gallagher, “That by far was the easiest installation and start-up I have ever experienced with any piece of equipment.” He adds, “Since install, we are now producing a quality, glue-sealed case with minimal downtime and preventive maintenance issues.”


From manual to automated


Nonni’s operates four production plants in the U.S., including the 50,000-sq-ft Ferndale location, which also provides space for warehousing and offices. At the Ferndale plant, a single line is used to produce a range of biscotti flavors that are individually wrapped in clear film and then either loaded into an eight- or 10-count tray, and packed in a secondary carton, or packed in a plastic tub for club-store sale. Before the upgrade, Nonni’s hand-packed its shipping cases with the filled and sealed secondary packs.

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