INTRODUCTION OF THE PROJECT
This spring Greenyard Frozen came to Barias with a special order. For one of their strategic customers in the USA the Convenience department developed gluten free and organic cauliflower rice with seasoning, bag-in-bag packed in a display box.
This assignment required a particularly complex production and packaging process with a mix of automated and manual operations. Discover below how we used our expertise and service for this project.
THE MISSION OF GREENYARD
Valentijn Verhaeghe, business unit manager of Greenyard Convenience: "We recently developed a whole range of recipes based on cauliflower rice. This trendy and innovative product is perfectly suited to be prepared in an individual steamer bag, so we are also marketing it in a matching and convenient type of packaging."
For a strategic customer in the USA, Greenyard went a step further and developed a gluten-free and organic version with seasoning, packaged in an innovative bag-in-bag packaging as well as in a display box, ready to put on the shelf.
"This innovative project involved a complex production and packaging process with a mix of automated and manual operations that was difficult to organize in-house, so we immediately decided to outsource the entire packaging project."
THE PACKAGING PROCESS IN THE SPOTLIGHT
As early as the conceptual phase, we collaborated with Barias on this elaborate packaging process, in which the cauliflower rice is first packed in small steamable bags and then in omzaks per four.
1. Bag-in-bag packaging .
First, the cauliflower rice is weighed on the packaging line of our GEA SmartPacker CX400 with Ishida weighing instruments and packed in small steam bags of 340 grams.
This is where our customer makes its first efficiency move: such small packages cause a delay on the machine, making it more cost-effective for the customer to outsource this.
The steam bags are then packed in turnkey bags in groups of four on the multihead.
This bag-in-bag packaging then enters the bunker and from this point in the packaging process the manual work begins.
2. Manual filling of display boxes
The outer bags are manually placed in a cardboard display box per six from the bunker.
This box is opened by our people and then stacked on the pallet by hand. This way, the containers are filled and shipped to the USA.
3. The biochain is insured
This gluten-free cauliflower rice is an organic product.
Because we at Barias are also certified organic, we can ensure the organic chain of cauliflower rice during packing and storage.
THE ADDED VALUE OF BARIAS
A dealbreaker for Greenyard's American client was to be able to place the boxes directly on the shelf upon delivery so that the store personnel would have no further work to do.
This was only possible by combining the automatic packaging process with manual operations, an atypical process for which Greenyard Frozen's own machinery is not adapted and for which no manpower is available.
Regardless of the size of the order, this is a flexibility that we can guarantee at Barias.
See how Valentijn Verhaeghe of Greenyard experiences the collaboration with Barias.
Do you have a similar project for which you can use our expertise and support?
Please do not hesitate to contact
Bert Tyberghien via bert.tyberghien@barias.be or
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