Reducing wastage to help US ready meals firm make huge savings

Reducing wastage to help US ready meals firm make huge savings

What the client needed

Our client is one of the largest frozen ready meals producers in the US, making two million meals every day at three manufacturing facilities. The firm contacted Apple when it wanted to replace one of its depositing machines which was being used to apply gravy and sauces to ready meal trays and was losing significant amounts through lack of accuracy.

What we did

With its previous equipment, our client had been losing around 10-12 grammes in wastage per ready meal. This production line processes 120 meals per minute on a two-shift, six-day system, so even a small amount of wastage on each tray adds up to large quantities overall. We could guarantee that our super-efficient, high speed food depositor, the RBB300, would eliminate 85% of its food waste. After a six-month period we were asked to supply a replacement for another depositor system on the ready meals production line: an eight-head system operating at a rate of 240 meals per minute. A bespoke hybrid depositing unit, manufactured to the client’s specific requirements, was delivered and installed and the equipment was fully working within six days. Orders for a further two eight-head depositors followed shortly afterwards.

The outcome

The efficiency of our equipment helped our client make savings on production lines of between US$500 and US$1,500 per shift in waste product alone. The commissioning engineering consultant at our client said: “When you consider that we have more than 20 production lines producing well over a million meals per day, the investment in high accuracy depositors from Apple International made absolute sense.”

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What our clients are saying:

  • “I would without hesitation, recommend Apple Food Systems to anyone who is looking for high quality depositors, transfer pumps, bespoke equipment or accessories for existing equipment that is not necessarily made by Apple as they have made for us.”

    Mark Scholey, Group Operations Manager Savoury - David Wood Foods

  • “The machine supplied to us by Apple Food Systems was built to a very high standard and works tirelessly every day without any hitches. The cleaning of the machine is also effortless and makes for a high standard product easily achievable.”

    Rob Normington
, Manufacturing Manager - JDM Food Group

  • “Apple have helped us in developing various projects allowing us to meet the requirements of our customers. The help and response has always been prompt and has allowed us to fast track new projects on, at times, extremely tight schedules.”

    Operations Manager

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