Case Study - Deldiche (Gourmet food & Convenience)
Deldiche automates end-of-line packaging - More efficient cartoning for hummus, olive paste and high-quality sausage products
Ternat, Belgium, 15.03.2023: Deldiche, a Belgian manufacturer of hummus, pesto, olive paste and high-quality sausage products, has automated its packaging process. Since October 2022, a state-of-the-art SOMIC packaging machine has been cartoning the products. With a speed of up to 30 cartons per minute, this machine packs the delicacies efficiently and saves space.
In recent years, the Belgian manufacturer of delicatessen products Deldiche has experienced rapid growth. Just a few years ago, the company had two semi-automatic packaging lines, but now it has five. Unlike many other industries, Deldiche has benefited from the increasing demand for delicatessen products in grocery stores and department stores during the coronavirus pandemic.
Complex and versatile packaging process
The packaging process at Deldiche is extremely demanding, particularly with regard to the different sizes of the cups and the varying number of products per carton. This complexity makes automating the process a major challenge. “Deldiche supplies well-known retailers in Belgium and internationally, as well as the food and retail sectors, including butchers and delicatessens,” explains Technical Manager Koen Ryssaert.
Quality is right at the top of Deldiche's list of priorities. The products are based on in-house recipes, for which head chef Christer Elfving is responsible. Elfving is constantly working on new creations. “To ensure the freshness and quality of the products, they are carefully stored immediately after production,” says Elfving. A tour of the production facility shows that the time between production and packaging is kept to a minimum in order to guarantee maximum freshness at all times.
Efficient packaging solution for Deldiche
The cups at Deldiche are filled and sealed on longitudinal or rotary packaging lines as required.Customers have the option of finishing their products with individual trimmings. A protective atmosphere can be added to extend the shelf life. After labeling, a precise weight check is carried out before the cups are inkjet coded. This is followed by final packaging.
Where the cups were previously packed manually in boxes, a SOMIC end-of-line packaging machine now takes over the work. The cups are transported on a conveyor belt into the SOMIC Wraparound Packer, where they are collected, grouped and packed into a carton in a way that protects the product. Depending on the size of the cups, a one-piece wraparound carton is folded around the cups so that there is no unnecessary empty space and the products are packed securely. This not only prevents the cups from slipping, but also ensures that the available space in the carton is used efficiently. After packaging, the filled cartons are ready for labeling and palletizing. The cartons are currently still palletized manually, but plans for fully automatic palletizing are already being considered.
Flexible packaging solutions: The switch from reusable crates to cardboard packaging
Deldiche originally relied on packaging in flowpacks and reusable EPS crates. However, as demand increased, the company had to look for environmentally friendly solutions that could cope with the increased production figures. “You use a crate several times, a box only once. But transporting the crates back is also complex,” explains Operations Manager Sara Selis. “The crates also have to be washed after each use.”
International customers in particular are increasingly looking for carton packaging, which prompted Deldiche to invest in a highly flexible SOMIC packaging machine. This machine is specially designed to handle different pack sizes and carton contents. This means that it can pack different cup sizes - from smaller variants with a diameter of 95 mm and a filling volume of 150 grams to larger cups with a diameter of 115 mm and a content of 450 grams. Duo and trio cups are also possible. Depending on customer requirements, the cups are packed in either one or two layers - and all with one machine.
With the SOMIC wraparound packer, Deldiche can cover a total of ten different formats with one machine. Thanks to the SOMIC QuickChange technology, changing between the different carton formats is quick and easy. Operators receive a manual that describes the format change in clear, comprehensible steps so that the process can be carried out easily and without tools. In addition, the machine automatically checks whether the changeover has been carried out correctly. If there are any deviations, the touchscreen shows exactly what needs to be corrected so that the machine can switch to operating mode. This is the only way to guarantee the shortest possible machine downtime.
Targeted staff training and intuitive menu navigation on the touchscreen ensure that the SOMIC packaging machine is easy to operate. “Our employees don't need to be technicians, as is often the case with many other machines,” explains Sara Selis.
Enormous increase in efficiency through automation
The automation of the packaging process has significantly increased the speed at Deldiche. Whereas previously only four to five cartons per minute could be packed in manual operation, the machine now manages 20 to 30 cartons per minute. Another advantage is the space gain: “Previously, the cartons had to be ready folded, which took up valuable storage space. Thanks to the SOMIC Wraparound Packer, the cartons are now fed in flat, which saves us a lot of space,” explains Selis.
Automation also offers advantages in terms of personnel. The savings in full-time equivalents (FTEs) help to ensure that the investment in the machine pays for itself quickly. In addition, the automatic hot melt gluing in the packaging machine ensures further savings - previously this step was carried out manually with adhesive tape.
The new packaging machine not only brings greater efficiency, but also considerable ergonomic benefits for the employees. “We attach great importance to ergonomics,” emphasizes Koen Ryssaert. Previously, the boxes had to be folded manually and the cups laboriously inserted into the cartons, which resulted in strenuous twisting movements for the back. Thanks to automation, much of this physical strain is no longer necessary. Now the cartons only have to be manually stacked on pallets, which significantly reduces the physical strain. The reduced number of manual movements also makes it easier to combine this activity with other tasks.
Compact and efficient solution
Due to the limited space available in the production hall at Deldiche, the smallest possible footprint of the machine was particularly important. With its compact design, the SOMIC wraparound packer has a footprint of 3.5 by 3.5 meters and a height of 2.6 meters. Additional space is saved by feeding the products from the side.
“We didn't opt for the cheapest solution, but for a long-lasting packaging machine that will also offer us security in the future without us having to worry about the availability of spare parts,” explains Koen Ryssaert. SOMIC works exclusively with renowned suppliers such as Festo and Schneider Electric for the control technology.
The option of remote maintenance is another major advantage of SOMIC packaging machines. If necessary, settings can be tested or adjusted without the need for a service technician on site. This close technical support ensures smooth production. There is also an established partnership between SOMIC and carton supplier VPK, which benefits Deldiche. “It's a huge advantage for us that we work closely together,” explains Koen Ryssaert. “Both know each other's tolerances inside out, which ensures optimum packaging quality.”
In consultation with VPK, Deldiche has chosen a carton type that has proven itself in 6-degree cooling in relation to the product weight. “This allows us to offer solution-oriented packaging that meets the requirements of the retail trade,” adds Sara Selis.
Deldiche in figures
Deldiche, a Belgian family business, was founded in 1990 and now has an annual turnover of around 30 million euros. The company employs 90 full-time staff and specializes in the production and distribution of hummus, pesto, fresh olive pastes and a variety of tapas, antipasti, mezze and vegetarian, fish and meat specialties.
In addition to the Belgian market, Deldiche supplies major retailers throughout Europe, including the Netherlands, Luxembourg, Spain, the United Kingdom, Ireland, Sweden, Norway, Romania and Poland. The use of sustainable materials is particularly noteworthy: the cups used are made from at least 90 percent recycled RPET and the company has held a CO2-neutral label for several years, which demonstrates its commitment to the environment.
Images: DELDICHE, ERIK KRUISSELBRINK