The Dutch family business Peka Kroef has long made a name for itself in the global potato industry. To achieve this, the company relies on a high degree of automation. One of the latest components are the Industry 4.0-compatible TX 820 series packaging machines from Multivac.
Peka Kroef processes the house potato into fresh, pasteurised specialities: The so-called Hansa potato is turned into many different shapes, such as wedges, gratins and purees. Produced for supermarkets, restaurants and catering companies, the delicacies are exported to more than 15 countries with growing success.
Packaging marinated potatoes
In order to be able to process and pack many millions of potatoes every year, the company relies not only on qualified employees, but also on on a high degree of automation in production and storage. Plants, some several storeys high, automatically sort potatoes delivered to a factory according to quality and wash, steam peel, cut and process them into the end product. The entire production process is monitored and controlled by experts in a control room on a monitor wall. The primary aim is to increase efficiency in production and logistics. This also applies to a system that packs marinated potatoes in aluminium trays. Peka Kroef recognised room for improvement here.
„We were looking for more capacity and flexibility to keep our production process running around the clock. We wanted a packaging machine that never misses a cycle, where the supply of aluminium containers is continuous and where labelling is part of the packaging process. The new TX 820 can do just that.“
Arjen de Groot, Project Manager Engineering at Peka Kroef
More capacity for 24/7 production
The new TX 820 traysealer from Multivac are used at the production sites in Odiliapeel and Asten. There, the machines are used to pack and label marinated potatoes. The only manual task here is to place aluminium trays in stacks of around 150 onto a feed system. From this moment on, the machine takes over. The stacks move into a holding device. There, the trays are separated onto another conveyor belt, which is located one level lower. In the next step, the marinated potatoes fall into the trays via a dosing system. Once the containers are filled, the traysealer seals them with a thin top film. The tools, known as X-tools, ensure that the sealing forces are evenly distributed across the trays. This guarantees a uniform and reliable sealing result, even at high cycle outputs and in multi-shift operation. After sealing, labelling is carried out using the L 310 Full Wrap conveyor belt labeller from Multivac. It dispenses the elongated label with nutritional information, product photo and company logo onto the top of the film. Two mechanical devices mounted to the right and left of the conveyor belt press the ends against the film as it passes over, so that the label encloses the packaging on four sides. The marinated potatoes are then ready for delivery.
Replacing the machines in a rush
Peka Kroef decided to work with Multivac not only because of the reliability and performance. The commissioning of the new packaging line should also result in as little interruption to production as possible. Multivac has developed from a pure machine supplier into a solution provider that enables one-stop shopping. This provides customers with homogeneous lines consisting of machines with harmonised interfaces. The one-stop shop principle ensures less coordination effort and accelerated project phases.
„During the preparation phase, our operators and engineers travelled to the Multivac plant in Germany. There we were informed about our wishes and requirements. In addition, the upgrade was carefully prepared in advance. A detailed test plan was drawn up. We wanted to know exactly how the replacement would work. Completion of the replacement project went smoothly and quickly: the machines were purchased and then installed in a short space of time. The old ones out, the new ones in. In Asten, we did it in 24 hours. In Odiliapeel in 72 hours.“
Josjo Uithol, Commercial Manager at Peka Kroef
Optimisation of production in real time
With the upgrade of the packaging machines, Peka Kroef also continued to drive forward the digitalisation of the company. The Multivac line is equipped with sensors and integrated into the company's higher-level computer system. This makes it possible to use data analyses to optimise the packaging process in real time and identify bottlenecks and impending errors at an early stage. „The employees are also satisfied with the simple operation,“ says Arjen. This is done via a touchscreen terminal that supports users with graphics. All machines in the line can be operated and orchestrated from a single point. This also leads to higher productivity. „We look back on the project with satisfaction. Both corporate cultures fit well together: hard work, a no-nonsense and practical approach - and just like Multivac, the family-run company Peka Kroef has been around for around half a century.“
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