Greencore Grocery reaps the benefits of a Kliklok ELITE wraparound cartoner

Increasing the convenience and product offering to its customers, Greencore Grocery, a manufacturer of ambient grocery products, including savoury dips for major supermarket chains, chose to install a Kliklok ELITE wrap-around cartoner at its facility in Selby, North Yorkshire in the UK.

The Kliklok ELITE was engineered as an evolution of previous models, with a strong emphasis on design, build and functionality to accommodate the wide variety of products seen in today’s food industry.

Greencore has a model called The Greencore Way, which it uses to drive success for the business and its stakeholders. The Greencore Way is centred on four key principles: ‘People at the Core’, ‘Great Food’, ‘Business Effectiveness’ and ‘Cost Efficiency’.

This was evident in the thinking behind the decision to choose the Kliklok ELITE. Holly Barber, Project Engineer at Greencore Grocery commented:

We needed a wrap-around cartoner that would give us the flexibility to carry out operations on various savoury dip pots and packaging formats, and the ELITE has delivered exactly on brief.

In addition to providing the flexibility Greencore required at its Selby site, the integrated functions have also proven to be invaluable to the production team. Greencore has a barcode reader, set to initiate on detection of any incorrect barcodes, and a mechanism to control stacked products inside the machine itself. This detect and stop feature manages any pots that happen to fall inside the system and alerts operators straight away to avoid extended unscheduled downtime.

Consumer convenience is key    

Greencore required a ‘future-proof’ system that was able to package single pot savoury dips and also a two-part product containing a pasta pot with separate sauce pot inverted on top. The latter being the more complicated item to handle, the ELITE solution sees the bottom or base pots arriving in balanced lanes in the correct alignment, while the top layer is produced via an inclined conveyor onto a dead plate and side chain transfer. The top pot arrives at the ELITE infeed and is taken up and over, inverted and then positioned on top of the base pot.

Complying with strict factory requirements

In addition, the ELITE was constructed to comply with Greencore’s factory specifications and requirements specifically. It is IP65 rated for washdown purposes and includes a build back sensor to pause the machine infeed to prevent the over-stuffing of products. The ELITE is also PackML ready with common SCADA and MES inputs. PackML provides defined machine status and operational flow, alongside critical Overall Equipment Effectiveness (OEE) and root Cause analysis (RCA) data.

Ady Moore, Shift Manager at Greencore Selby said:

I have been in this industry for over 30 years, and the Kliklok ELITE is the most unique and efficient packing machine I have seen. We are delighted with its performance.

Bosch was very pleased to continue its relationship with Greencore at its Selby site and are confident the ELITE will perform exactly to the company’s requirements for these applications. The company understands entirely the need for flexibility in today’s competitive food industry and always endeavours to work in partnership with its customers to ensure solutions are 100% fit-for-purpose. The ELITE system in Selby is a prime example of this commitment to service and quality and Bosch looks forward to working with the wider Greencore Group on future projects across its multiple sites.

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