Case Study - mixing frozen vegetables

In March 1999 Cox and Plant received an enquiry from the leading Polish manufacturer of branded fruit juices and a significant producer of frozen fruit and mixed vegetables. It is also one of the largest food-processing companies in central Europe.

The request was for a complete mixing line which involved up to 8 different frozen vegetables at a throughput of 10 tonnes per hour.

The two projects were scheduled for delivery in September 1999 with a final requirement for 96 different machines for two of their factories based in Southern Poland and outside Warsaw.

Our customer wished to expand as they previously mixed every kilo by hand. This resulted in huge variations as every kilo was plus or minus 30%. This also meant that a hand mixed line generated huge giveaways, with operatives not distinguishing between high and low value product. As the company entered more sophisticated markets their techniques needed improving and cost saving was required, hence the need for automation.

Cox and Plant provided the total project management ; from scooping the project and assisting with the factory layout, to designing all the machines in CAD and manufacturing most of the plant, to commissioning the lines.

The move towards automation was challenging for the workforce and Cox and Plant further assisted by constructing teaching programmes for different operative and supervisory groups.

Overall, Cox and Plant provided 96 different machines including vibratory conveyors , flighted elevators , lift and tip box tippers and rotary mixing drums. The capital cost justification was based on projected savings, which were realised after one year.