Snack food manufacturer speeds up case packing throughput

Established in 1984, Majans produces over two million cases of snacks each year across a range of 53 products. In order to meet its ambitious growth plans, the company has now deployed a TNA solutions case packing technology that has helped to deliver a 140% throughput increase in just 12 months.

The tna ropac 5 technology has been deployed to automate Majans’ case packing operations. At a capacity of 200 bags/min, it features a bag conditioner, case packer, case erector and checkweigher.

“I’d seen TNA baggers working perfectly after 40 years of service, and I knew we were on track when we made the decision to partner with TNA at Majans,” said the Manufacturing Manager at Majans, Andrew McManus.

“With a TNA flavouring system and tna robag baggers already in place, we knew we would benefit from the interchangeable aspects of a TNA solution for case packing — particularly from an electronics perspective, and also the consistency of the HMI interface for our technicians.

“Introducing tna ropac 5 systems has enabled us to improve operational efficiency, redistribute manpower and futureproof our operations as we look to continue our growth path,” McManus said.

Majans currently uses around 70% of the tna ropac capacity of 200 bags/min, but future increases have been factored in.

Since its introduction in February 2023, throughput performance has increased by 140% and uptime by 15%. The system is also able to accommodate the company’s plans to move to paper-based packaging in 2024, supporting its sustainable development plans without impacting production speeds.

“Just five years ago, Majans regularly had between 28 and 35 people on a single shift, bagging, mixing and case packing. Today, with the help of TNA solutions, that same factory operates with just 10–11 people per shift at outputs up to 6.9 times greater than before the automation process began. Casual jobs have been transformed into stable, full-time employment contracts and technicians and maintenance crews have also been upskilled to effectively service and support these systems at a higher technology level,” McManus said.

Image credit: TNA solutions.