Kaufland increases capacity in the meat packing center
Automation has significantly improved Kaufland's meat packing center in Osterfeld, Germany. By implementing a customized tray denesting and product loading solution from Qupaq, Kaufland can now achieve output from one packaging line that previously required two. This has translated into cost savings in staffing and ongoing maintenance.
After successfully integrating a Qupaq solution at its meat packing center in Möckmühl in 2017, German hypermarket chain Kaufland initiated a similar investment for its Osterfeld facility earlier this year.
The project was completed in August and the main goal is to increase efficiency and reduce maintenance costs through automation. In fact, Kaufland can now achieve what previously required two minced meat portioning lines with just one, significantly increasing their operational capacity.
"By implementing the right automation solutions, we can reduce costs and address a growing challenge in the food industry: limited access to skilled labor. We turned to Qupaq because we were encountering issues with limited space at our meat packing center in Osterfeld and "We wanted to increase our production performance. The system we implemented in Möckmühl did exactly that, and that's why we decided to invest in a similar solution for our facility in Osterfeld," explains Christopher Mader, Head of Operations at Kaufland .
Increased efficiency and reduced costs
The Qupaq solution, although based on standard modules, is tailored to Kaufland's specifications. The system includes the Anytray CleanLine Denester, complemented by a buffer and a servo stirring mechanism, as well as a loader that fills the trays with speed and accuracy. An essential part of the system's efficiency is the diverger, which directs the trays to their designated side of the split belt while a pusher aligns them for sealing. This synergy between components creates fluid, high-performance operation with a line feeding two sealing machines for maximum capacity.
"Prior to installing the new Qupaq solution, our facility consisted of two separate tray denesting and loading systems connected to our meat processing unit. This created challenges in efficiency, coordination and increased maintenance costs. With Qupaq we are focused on a single cohesive Switched to a solution that feeds both sealing machines at around 60 portions per minute. The installation has significantly improved our operation by making it more efficient and cost effective. The mechanical integration of the packaging line was straightforward and well planned, while feedback from our production team states that "It's easy to use," explains Christopher Mader.
Combining tray denesting and portioning has simplified production and resulted in significant time savings. This efficiency is evident in daily operations, with fewer interruptions, increased productivity and accelerated turnaround times. A standout benefit was consistent uptime, ensuring Kaufland's meat packing processes run smoothly and without unnecessary delays.
Support transitions to automation
Food manufacturers worldwide must navigate complex challenges with rising costs and a call for reduced, ever-evolving compliance regulations. As a result, the need for streamlined operations has never been greater. In order to construct the most efficient solutions, Qupaq uses standard solutions adapted to the customer's needs. It was important for Kaufland to find the most suitable components to meet the capacity requirements.
"Although we offer standard modules, it is crucial to establish a streamlined process up front to create the best solutions. We pride ourselves on our ability to create adaptable solutions, ensuring they match our customers' needs. In In Germany, the food industry operates at high capacity, making efficiency a critical factor. We are proud to help one of the largest hypermarket chains in Germany move to more efficient automation," says Lars Zederkof, CSO at Qupaq.
The collaboration between Kaufland and Qupaq highlights the critical role of tailored automation in increasing operational efficiency. It sets a precedent in the industry and highlights how innovative technologies can pragmatically address the challenges of the food industry.
About Qupaq A/S
Headquartered in Brønderslev, Denmark, Qupaq is the world's leading provider of tray denesting solutions for the food industry. The company's automated denesting solutions process over 10 billion food packaging trays annually in over 50 markets.
Qupaq's product portfolio consists of the world's most comprehensive modular range of diesters, conveyors and equipment for efficient tray handling and product loading. It includes both the global leader in electric denesting equipment, Intray, and the global leader in pneumatic denesting equipment, Anytray. For more information, see www.qupaq.com.
With rising pressures and costs from inflation and calls for reduced environmental impact, the food industry is looking for valuable tools to meet the challenges. Automation stands out as a transformative force that is redefining operations and driving efficiency.
