Leading Italian snack manufacturer Pata was able to reduce waste, simplify cleaning operations and improve overall production efficiencies by choosing packaging, weighing, seasoning and distribution systems from integrated packaging and processing solutions provider tna.
Based in the province of Mantua, Italy, Pata specialises in the production of a wide variety of potato chips, popcorn, and extruded snacks. Pata continuously strives to employ the latest technology for its 17 production lines and was looking for a supplier that could deliver both on quality and innovative, hygienic design to improve production efficiencies at its plant.
Increased bagging speeds
Responsible for producing a wide variety of snacks, for their own brand and also for third parties, Pata needed a flexible packaging system that could handle different products and bag sizes. At the same time, the company was looking to optimise production by increasing bagging speeds and reducing waste.
The tna robag® TX 3ci vertical form, fill and seal (VFFS) packaging system was able to offer both production flexibility and improved performance in a compact, easy-to-clean system. Designed with flexibility in mind and capable of delivering up to 100 bags per minute, the tna robag TX 3ci handles a wide variety of bag sizes and formats, while its rotary single jaws ensure seal integrity, preventing bursts and reducing waste.
The system was delivered completely integrated with a tna intelli-weigh® 0314S omega multi-head high speed scale. Capable of up to 200 weighs per minute, the tna intelli-weigh 0314S omega offers high accuracy, further improving performance by reducing product losses. In addition, tna ensured the seamless integration of a stainless steel metal detector to make sure Pata’s high standards of hygiene and safety were maintained.
Improved flavour consistency
Seasoning is a key challenge for any snack manufacturer. Each type of snack base product has its own set of attributes, unique product structure, surface and topography which can challenge the application needs. For Pata it was therefore important to find a seasoning system that was not only able to handle the versatile product range, but would also ensure even coverage and precise flavour diffusion to uphold Pata’s high demands on quality.
The installation of tna’s high performance intelli-flav® seasoning systems proved to be the ideal solution. The tna intelli-flav OMS 5 features a responsive variable mass seasoning system with dynamic vibratory weigher, which enables an accurate, proportional amount of seasoning to be evenly applied to the product for improved coverage and flavour dispersion. With a simple, modular design, tna’s intelli-flav seasoning systems are fully enclosed for increased levels of hygiene and ease of cleaning. Moreover, their 90-degree pivoting drum improves accessibility for hard to reach areas, simplifying day-to-day operations.
Reduced waste on the conveyer
When it came to choosing a conveyer, reduced product breakage and ease of cleaning were the deciding factors. In the past, products would break easily when travelling along the conveyer, resulting in material waste. At the same time, cleaning was a time-consuming and labour-intensive process as crumbs would regularly accumulate in hard to reach places.
tna roflo® VM conveyors with accumulation capability were installed to gently distribute products along the production line. Using a unique vibratory motion and a dimpled surface, the specially designed conveyors allow for smooth product flow, minimising the risk of product breakage and rejects. Furthermore, the easy-to-clean design of the tna roflo VM reduces downtime and helps manufacturers to comply with the highest food quality standards.
“As a food manufacturer, hygiene is naturally one of our top priorities,” adds Piona. “All of tna’s machines are really easy to clean. This has saved us a lot of time and we are really starting to notice the impact this has had on our production efficiencies.”
