Moving on the Fast Lane to Automation

Transforming a bar and catering business into a wholesale snack business was not an easy transition. As is often the case with small family run operations, Aleece's production was largely dependant on manual labor. However, once the pita chips were introduced to local markets, an influx of large orders flooded in. "We could not fulfill these orders manually and in an efficient manner. "We made the decision to research equipment that would help us increase our productivity," says Anthony.

The search for increased automation led Alice Anthony to PACK EXPO. Needing an efficient means of moving chips from the oven to final package, conveying and scaling machinery was high on the shopping list for the Aleece's Pita Chips.

With over 1,700 exhibitors providing solutions for all levels of the packaging supply chain, PACK EXPO provided an ideal location for Anthony to find the equipment she desired. After meeting with several vendors and some careful research, Anthony sought the expertise of WeighPack Systems, Inc. (Las Vegas, Nevada) to help with her needs.

"Following the show, a WeighPack representative visited our facility and helped us decide on what would work best with our product." The visit resulted in the purchase of a new incline infeed conveying system and WeighPack Tiger Scale™.

Available in 1-, 2-, 3- and 4-lane configurations, WeighPack Tiger Scales™ can accurately weigh products from 5 grams to over 100 pounds. The scales are modular in design, USDA approved and meet all HACCP criteria. In tandem with the incline infeed conveyor, the system allows for near seamless production.

"Prior to purchasing the new equipment we'd bake the chips, hand pack them in single-serve bags and weigh them on a small scale. Everything was done manually," recalls Anthony. With the purchase of the new system, chips are now dropped into a hopper and carried by the infeed conveyor to the scale. With a press of a foot pedal, a precise amount of chips are dropped into waiting bags. The bags are then packed in boxes and shipped.

The current operation requires only one person to manage the scale and fill the bag. "In a matter of minutes, the job is complete. Our productivity has increased nearly 50%," claims Anthony.

Cutting Pita and Cutting Costs

With the new system, Aleece's Pita Chips were efficiently manufacturing the increasingly popular snack faster that ever. But there was one more issue to overcome - cutting the chips. "We had to find a more efficient way of cutting the pita bread. This would also provide a way to trim additional production costs, since this process was also being accomplished manually."

Returning to PACK EXPO International in 2006, Alice met with FoodTools, Inc (South Haven, MI). Working with the engineering team, the two companies determined that the TS-1 Tortilla cutter provided the best solution to improve pita cutting and fit Aleece's specific requirements.

The TS-1 is a bench top unit typically designed to cut tortillas into strips quickly and efficiently. For Aleece's, the equipment was an ideal solution for cutting the pita chips into even portions. As hoped, the system also allowed Aleece's to reduce production costs.

"Previously, we often had to shut down our oven while the pita was being cut, which significantly increased our production time," remembers Anthony. The addition of the TS-1 eliminated the problem, allowing for the production line to flow without any starting and stopping.

Pita-Perfect

As orders steadily increase, Aleece's Pita Chips has begun planning for its next step towards minimizing manual operations and streamlining production. "We intend to visit the upcoming PACK EXPO International in Chicago to explore the latest in automation technology," says Anthony.

"PACK EXPO provides attendees with a valuable opportunity to meet with industry experts and discuss solutions pertinent to their own businesses," comments Anthony. "As we continue to expand, we know that the show will help us find new ways to improve the efficiency and productivity of our operations."