Aegean had an existing T 300 Traysealer which, while reliable, was no longer able to meet the increased throughput requirements necessary for the business’s growth. The factory floor space was restricted, and the manual production processes were becoming a bottleneck, hindering the ability to scale operations effectively. Aegean were receiving new opportunities with major UK retailers, and the need to increase production capacity to secure the new business was a pressing concern. The challenge was not only to advance throughput, but also to do so within the constraints of their existing factory layout.

Optimising Operations: Enhancing Output to Meet Demand

To address these challenges, Aegean Heritage knew they could trust their partnership with MULTIVAC UK and turned to them for support, working with Regional Sales Manager, Luke Gowen, on a new, comprehensive solution.

The new integrated line includes two TX720 Traysealers, I210 Checkweighers, I100 X-ray machines, and a LASKA KU65 Bowl Chopper. The upgrade was meticulously project managed by the team at MULTIVAC UK, ensuring seamless integration and overcoming significant challenges such as the working height differences between high care and low care areas on the manufacturing floor. The installation was carried out during summer, which is the busiest time of the year for Aegean, demonstrating MULTIVAC’s commitment to minimizing impact on production. The new setup not only increased efficiency but also incorporated advanced technologies such as gas flushing without vacuum, enabling the use of lightweight, low-cost die sets and eliminating the need for a vacuum pump, resulting in substantial energy savings.

Clear Results 

The implementation of the new machinery led to a dramatic increase in production capacity, boosting the maximum output from approximately 24 packs per minute (PPM), to over 60 ppm. This significant enhancement in efficiency allowed Aegean Heritage to reduce labour requirements by 1 operator per line, and the advanced technology achieved less than 2% residual oxygen values, ensuring excellent seal quality in foil trays. 

The flexibility of quick-change die sets also enabled seamless transitions between different product types, further optimising production processes. The integrated line provided by MULTIVAC ensured continued excellence and uptime, supported by their dedicated servicing team, and Aegean also chose to incorporate MULTIVAC Smart Services into their new kit, which gave access to a live production dashboard and tracking of under/overweight packs with their new checkweigher.

The successful installation has not only met the immediate growth needs but also positioned Aegean Heritage for future expansion.

A Testament to Strategic Partnership 

As with any project of this complexity, Aegean and MULTIVAC faced several challenges throughout, which was largely due to global parts and raw materials shortages. Despite these hurdles, MULTIVAC’s unwavering commitment to customer service ensured that Aegean Heritage could continue production with interim solutions, such as the supply of a bowl chopper to allow them to maintain production of their pesto marinade. The successful installation has led to increased output, acquisition of new business, and more positive feedback from end customers, who have praised both the pack appearance and quality. 

Looking ahead, the business already has future projects with MULTIVAC in the pipeline and intend to continue their journey in growth and efficiency.

Flawless Integration and World-class Aftersales Support

Aegean Heritage can now leverage the extensive and advanced support provided by MULTIVAC UK’s Technical Service Department. This ensures their new equipment operates at peak efficiency and availability, with access to over 60 regional service technicians and a dedicated technical helpdesk – all at no additional cost. MULTIVAC’s steadfast commitment to customer success has reinforced their position as a trusted partner for Aegean Heritage, guaranteeing ongoing excellence and reliability.