In one year more than 150 million litres of juice and squash flow through Rynkeby Foods A/S production in Ringe on the island of Funen and out to the consumers primarily in Denmark and Sweden. This is provided by the 240 employees. Approx. 55% of all juice and 60% of all squash consumed in Denmark come from Rynkeby.
Rynkeby has 75 years of experience producing juice and squash. For the last 20 years sales consultant Preben Bagger from PKI Supply has “lived” along as glue supplier. He has seen Rynkeby Foods A/S grow big through fusions and acquisitions by Scandinavian juice- and squash producers and in 1998 being owned 100% by the dairy-concern and –giant Arla Foods.
To Rynkeby Foods it is important that the production runs fluid.For the same reason a lean project is conducted in the company to optimize and cost-minimize the production process. A lean-project that project manager, Søren P. Jørgensen is responsible for. During this project is among other things usage and consumption of glue. The lean project started in the spring 2010.
Rynkeby uses 15 tonnes of glue per year divided between 4 types of of glue in the production process – 2 from PKI Supply and 2 from a competing company – which is used in the packaging plant for packing of trays and boxes containing ready-to-drink juice and squash drawn off to carton. This has later changed radically cf. the experiences Rynkeby has had.
New packing plant became a huge “glue-eye-opener”
Rynkeby Foods discovered the glue quality Technomelt Supra 120, a hotmelt from PKI Supply´s international business partner Henkel. This happened in connection with replacement of one of the 10 packing plants in the production, where the German supplier of the plant prescribed using this glue quality.
Until then Rynkeby had used a competing glue type for that part of the process.
- The old glue type caused a lot of production stoppages during the day because of cinders in the hoses and blocked nozzles entailing huge inconvenience for the employees at the packing plants and Rynkebys smith Kim B. Clemmensen, who is responsible for the service and maintenance of some of Rynkeby Foods´ packing plants, project manager Søren P. Jørgensen tells.
- Nozzle stoppage means loss of essential production time, where the process is stagnant. If the juice has been pasteurized and the drawing is not done within 24 hours, we must in worst case, pour out the juice.
PKI Supply was consulted right from the beginning
The new packing plant was installed. Preben Bagger participated from the beginning and the running-in was carried out in cooperation with Kim B. Clemmensen. Using the glue type Technomelt Supra 120 was a success from the very start! No machine stoppages. No blocked nozzles, no cinders in the hoses.
- On the basis of Preben Bagger´s recommendation, we tested similar glue on one of our old packing plants. Very early we experienced the good properties of the glue – no machine stops or lost production time, Søren P. Jørgensen tells. We raised our hands from the very first day.
An ongoing process was engineered changing the old glue type, this was phased out after 6 months.
The glue process in brief
The glue nozzle plots 2 ultrathin glue lines in each corner on top and bottom of the cardboard box. All this is done full-automatically on a conveyer and lightning quickly into the packing process, where the juice in pushes of 6-12 pcs. is shoved into the cardboard box. This passes a glue head that applies the 1500 C hot glue. At the same time 4 clamps hold the corners of the cardboard box once more in bottom and top for approx. 1-2 seconds for adhesion. Following the closed cardboard box is lifted by a robot to a euro-pallet. Ready for wrapping and transportation to the retail, where the consumers are ready to enjoy the fresh juice in the various numbers of flavors it is produced in.
High ROI-value despite that Supra 120 is more expensive than previously used glue types
Since Rynkeby Foods changed to Technomelt Supra 120 there has been no production stops – at all! A great satisfaction to Rynkeby Foods. This means a lot of extra production time. Mind you, efficient production time, Søren P. Jørgensen adds.
According to Kim B. Clemmensen not one single glue nozzle has been changed since. Financial this is a huge cost saving, since a new glue nozzle costs DKK 400-500 apiece. With 10 packing plants in the production this is a significant amount on a yearly basis, Søren P. Jørgensen tells.
Technomelt Supra 120 is not only better than previously used glue types, it is also more expensive. But not when the final sum is counted. For instance it has been possible to lower the temperature and pressure per bar, which has reduced the yearly glue consumption 25-30%.
PKI Supply also substitute themselves
As an extra feature PKI Supply does not only replace competing glue types – but also themselves. From previously having delivered 2 different glue types to Rynkeby Foods, now Technomelt Supra 120 is also used in the tapping machinery and in the packing plant with the small 0,25 liter packages, where the straw in the transparent plastic wrap is attached on the side with 2 X glue drops.
- Logistic it means today, that we have reduced the number of glue types from previously 4 types to only 1 – Technomelt Supra 120 - from PKI Supply, Søren P. Jørgensen states.
A lean-project was finished
Søren P. Jørgensen can now check mark one item of the total lean-project. Focus can now be shifted to the remaining items of the lean-project.