The demand for frozen French fries has been on a steady rise for years. Consumers worldwide are embracing the convenience of frozen potato products, driving potato processors to increase production. Aviko Germany, a key player in the potato processing industry, has responded by modernizing its operations at its Rain, Bavaria facility. To sustain high efficiency and meet the growing demand, the company has introduced Ishida’s high-performance CCW-RV multihead weighers, significantly boosting productivity.
Meeting Market Demands with Advanced Technology
Aviko Germany processes approximately 40 tons of potatoes per hour, transforming them into French fries, wedges, and other frozen potato products. The scale of this operation requires high-speed, high-precision packaging systems. To meet this need, Aviko has been replacing its older weighing systems with Ishida’s next-generation multihead weighers since 2023.
Currently, three of the outdated weighers have been replaced with Ishida’s CCW-RV series, with additional units scheduled for installation. The results are impressive: where previous models packed 50 bags per minute (ppm), the new weighers achieve up to 70 ppm for 450g bags. This represents a 40% increase in output, allowing Aviko to process significantly more product within the same timeframe.
Precision Weighing and Increased Efficiency
One of the key innovations of the CCW-RV series is its advanced weighing technology. The system selects the three best weight combinations per cycle, ensuring maximum accuracy while maintaining high speed. For instance, a 2.5kg bag is only overfilled by approximately 5g—equivalent to a single frozen fry. This level of precision reduces waste and maximizes cost efficiency for the company.
Moreover, the weighers feature five-stage digital filtering, which shortens the settling time of the weighing hoppers. This enhancement ensures a higher number of hoppers are ready for use at any given moment, streamlining the overall process.
Vibration Resistance for Consistent Accuracy
A common challenge in industrial environments is the impact of external vibrations on weighing accuracy. Ishida’s CCW-RV series tackles this issue with its Anti-Floor-Vibration (AFV) System. By compensating for floor vibrations through load cells positioned at the corners of the machine, the system maintains high precision even in dynamic factory settings. This innovation ensures that Aviko’s production remains uninterrupted and highly efficient.
Ease of Use and High Availability
Frequent product changeovers are a necessity in large-scale processing, and the CCW-RV weighers are designed to handle them seamlessly. Aviko benefits from quick preset configurations, reducing downtime between product shifts. Additionally, the weighers are equipped for high-pressure and steam-jet cleaning, with an IP69K-rated design that allows for thorough and rapid sanitation without affecting performance.
Sustainability and Energy Efficiency
Beyond performance improvements, Ishida’s weighers contribute to Aviko’s sustainability initiatives. These machines consume approximately 20% less energy than conventional models, with optional “Half-Power” and “Eco Mode” settings that can further reduce energy consumption by up to 50%. Given rising energy costs and increasing regulatory scrutiny, these efficiency gains are highly beneficial.
A Strategic Investment for the Future
Aviko anticipates a 2.5-year amortization period for its investment in Ishida’s weighers, underscoring the long-term financial viability of the upgrade. With the ability to pack larger product volumes efficiently, the company is well-positioned to meet the rising demand for frozen potato products in Germany, Switzerland, and Austria.
As a subsidiary of Aviko, one of the world’s largest potato processors backed by Royal Cosun’s financial strength, Aviko Germany continues to set industry benchmarks. By integrating cutting-edge weighing technology, the company not only enhances its operational efficiency but also strengthens its leadership in the global potato processing sector.
The implementation of Ishida’s CCW-RV multihead weighers has proven to be a game-changer for Aviko Germany. With a 40% increase in output, enhanced weighing precision, vibration resistance, and substantial energy savings, the company has successfully modernized its production facility to meet growing consumer demand. This strategic investment ensures that Aviko remains at the forefront of the frozen potato industry while optimizing its operational costs and sustainability efforts.
