Canadian-based Brandneu Foods has significantly reduced lead times for its popular range of kale chips by 75% after installing the high performance tna intelli-flav® OMS 5 at its plant in Toronto.
In addition to cutting production lead times from 60 days to just 15, the new installation has enabled Brandneu to consolidate work space, meaning it can respond more efficiently to customer demands for its products. To ensure a smooth installation, tna provided total project management services from start to finish.
Due to increased demand from consumers for healthier chips, Brandneu has seen the popularity of its kale chips soar. The company therefore needed to reevaluate its production capabilities in order to meet this demand and stay competitive in an increasingly crowded marketplace.
Improving seasoning accuracy
Brandneu had previously experienced problems with inconsistent flavoring, which had an impact on taste and resulted in significant seasoning losses. It was therefore vital for tna to provide a cutting-edge solution to ensure application accuracy and consistent coverage. Brandneu found that tna’s intelli-flav OMS 5 on-machine seasoning system was the solution. Providing both powder flavoring and liquid oil in a single drum, the system features a variable mass seasoning system with a dynamic vibratory weigher to control oil spray directly. This means that only the right amount of oil is applied to each chip, an essential consideration for Brandneu, who were keen to maintain the healthy nutritional profile of their popular kale chips.
Thanks to the system’s unparalleled accuracy of application, Brandneu was able to minimize seasoning losses in the production process, reducing raw material waste and increasing profitability. In addition, the tna intelli-flav OMS 5 offers improved coverage and flavor dispersion, enabling Brandneu to apply minimal salt and flavoring without compromising on the overall quality and taste of its kale chips.
Increasing production speeds
In order to meet the high demand for their product, Brandneu needed the flexibility to be able to change flavors quickly and easily. In response to this need, tna suggested a second drum that can be changed on the line in less than 15 minutes. The addition of the second drum means that Brandneu can meet orders more quickly and reduce production lead time by a substantial amount. This boost in production offers real customer satisfaction, and shows that Brandneu can be relied on to fulfill orders within a short turnaround time.
Seamless integration
As Brandneu wanted to maximize floor space for possible future expansions, tna needed to consider the overall footprint of the factory when planning the installation. Brandneu appreciated that, in addition to being simple and easy to use, the tna intelli-flav OMS 5 took up much less space than existing equipment, which provided them with the flexibility to add more lines in the future.
It was essential for tna to integrate the machine effortlessly with the other equipment. By analyzing Brandneu’s existing assets from start to finish, including its operational requirements and training needs, tna’s project management team was able to develop a solution that could be integrated quickly and seamlessly alongside Brandneu’s existing equipment.
Adrian Quinn, president of Brandneu Foods, comments, “Naturally, any production interruptions can be costly for manufacturers. We were very pleased with the speed with which the equipment was installed. Effectively acting as a ‘plug and play’ system, the line was up and running again within a few hours.”
