Dips stack up for Fresh Fodder thanks to filler technology

After experiencing a surge in demand due to the COVID-19 pandemic, Australian family-owned and -operated boutique producer of hand-crafted dips Fresh Fodder tripled its productivity rates. The achievement was helped by the Ilpra FS2500 Rotary Cup Filler — part of the packaging and lidding range from Jet Technologies.

After receiving new business from more than 400 Woolworths stores nationwide, Fresh Fodder reconsidered its technology investments.

The company understood they needed to maintain competitiveness within today’s fast-paced grocery market to meet their growing customer needs.

“As demand began to rapidly pick up, there soon came a point where our previous operational capabilities were outrun, which is where the investment in the FS2500 came into play as a crucial tool to increase our productivity and efficiency levels,” said Max Schofield, Managing Director of Fresh Fodder. “As all of this was happening right in the middle of the pandemic, we needed a solution fast. Thankfully, Jet Technologies was able to organise and install the new machine in a very tight timeframe, which helped us greatly throughout COVID-19 and to meet the high demand coming from Woolworths.”

Based in Orange, NSW, Fresh Fodder produces 15 tonnes of product per week across 12 different flavours in both retail packs and foodservice bulk sizes, distributing nationwide to stores such as Woolworths, Aldi, IGA Supermarkets, COSTCO, Harris Farm Markets and independent grocers, fruit markets, cafes and delis.

“The investment in the Illpra FS2500 was part of a holistic upgrade of our production floor, as well as our business-wide plans to optimise operations with technology and improve the quality of our products,” Schofield said.

Since the machine was installed in October 2020, the company has streamlined its manufacturing to produce three times the amount of its existing throughput with the same headcount of staff.

“This has had the biggest overall impact on our bottom line. As a business, we are now seeing a huge 25% growth year-on-year, so upgrading to this new solution allows us to optimise operations and keep up with our current and future growth.”

The FS2500, from Italian packaging manufacturer Ilpra, is a mechanical rotary filling and sealing machine with eight stations designed to fill dispensable plastic cups and containers with liquid and semi-solid products.

Part of Jet Technologies’ range of fill seal solutions, the device is suitable for a range of products including dairy, dips, cosmetics, pharmaceuticals, desserts and ready-made meals.

Daniel Malki, Director of Jet Technologies, said the company was glad to help Fresh Fodder prosper during difficult times.

“With countless changes to the market, global and local supply chains have become very hard to manoeuvre, which has challenged countless industries to find an innovative means of adapting. So, it is fantastic to see Australian businesses such as Fresh Fodder taking such a proactive approach to addressing these challenges head on, by investing in technology that helps to futureproof their manufacturing operations,” he said.