Delkor Dare Foods

Quebec bakery’s automation investment hits the packaging line efficiency sweet spot

Sept. 2014 - No manufacturer of global renown has ever gotten to be that way without daring to set high goals for itself, and Kitchener, Ont.-headquartered Dare Foods Limited is as fine a testament to the vir­tues of dreaming big and reaching high as any major Canadian food producer out there—even after more than 120 years in the highly competitive baked-goods business.

Founded in 1892 by Charles Henry Doerr under the name of C.H. Doerr Company, the family-owned business that rose to iconic promi­nence as a manufacturer of delicious, high-quality cookies is nowadays also a major North American player in the market segments for crackers, fine breads, candies and other baked good­ies and treats that busy modern-day consumers can’t seem to get enough of—including the very popular line of snack-bread products produced at the company’s highly-automated, 140-employee breadmaking facility in Saint-Martin, Que.

One of six manufacturing plants operated by Dare Foods in North America—employing over 1,300 people in total—the Saint-Martin plant is home to the company’s very popular line of Boulangerie Grissol brand portfolio purchased by Dare Foods in its 2001 acquisition of the cookie and fine breads business of the Montreal-based Culinar Inc.

Housing two baking lines and three packaging lines, the busy plant turns out the full range of Boulangerie Grissolbrand products, including the perennial bestseller Melba toast, CanapéBread Sticks and Baguette Bites, along with the re­cently-lunched new favorites such as Morning Thins, thin crispy slices of bakerystyle loaves with seeds, fiber and fruit for on-the-go mornings; Sweet Thins, a sweet calorie-con­trolled snack; and Artisanal Ba­guettes, a line of premium quality, oven-baked baguettes made under authentic recipes and using fresh natural ingredients like black olives, cinnamon and raisin, or cranberry and figs.

Lead Role

“We are a leading Canadian fine bread manufacturer,” says Saint-Martin maintenance manag­er Matthew Beauchamp, noting the company considers itself to be one of the leading players in the fine bread market segment across North America, despite growing compe­tition from both imports and pri­vate-label store brands.

“Increased competition is a reality for us,” Beauchamp told Canadian Packaging in a recent interview, “but we constantly strive to remain competitive by launching new and innovative products.”

“We also look at our bot­tom line results with the realiza­tion that by constantly updating our manufacturing equipment, we will not only improve our produc­tion line speed and efficiency, but will also reduce our manufactur­ing costs,” says Beauchamp, citing four major facility expansions and innumerable equipment upgrades taking place at the Saint-Martin fac­tory since it first started producing the venerable Boulangerie Grissol products back in the 1940s under previous owners.

As the plant’s maintenance manager, it is Beauchamp’s job to ensure the plant’s production and packaging lines are always running up to snuff, which is no easy task for a plant “producing on three shifts a day, covering the entire week—with regu­larly scheduled sanitation—24-hours-a-day and seven-days-a-week.”

Despite the plant’s high-throughput rates and growing volumes, Beauchamp says the facility does not take any shortcuts that would in any way undermine the final qual­ity of the product manufactured at Saint-Martin.

“After fresh ingredients are mixed in batches to produce dough, we process it into various pans, and bake it in large ovens,” he relates. “Af­ter depanning, the cooked loaves are placed onto large wheeled racks and are refrigerated for several days to en­sure most of the humidity is removed.

“Removing it from the refrig­erated section, we slice the now-dry bread, and further toast it on a pro­cessing line specific to the type of cut and packaging required,” Beauchamp expands.

“After packaging—either semi-automatically or fully-automati­cally—the packaged products are pal­letized and immediately placed into vans for shipment to our distribution center which will then ensure our products go to the proper destination.”

For a company that is often credited with rewriting the book on cookie packaging in Canada, having borrowed a trick from coffee packag­ing and introducing the tin-tie strip to cookie packaging in 1954 to make it a new de facto cookie industry stan­dard, the performance of packag­ing machinery and equipment at the Saint-Martin facility naturally get all the close scrutiny and attention it duly deserves, according to Beauchamp.

“When I became the mainte­nance manager for the Saint-Martin plant last year, I noticed early on that an existing carton former that was in use on one of our major line was not up to par,” he says.

“Relative to our needs, it was a poor design that featured overly compli­cated changeovers and adjustments that, quite frankly, caused us a lot of unnecessary downtime.

“Back in the summer of 2011, I was looking for a simple, robust, yet high-per­formance design with a high level of perfor­mance and efficiency, and I found one that offered all of that in one,” relates

Beauchamp. “We found that at Delkor.”

Delkor Systems, Inc., a St. Paul, Minnesota headquartered designer and manufacturer of packaging machinery, installed a brand-new Trayfecta S4 1502 model case, carton and tray former at the Saint-Martin facility.

According to Beauchamp, it was when he worked for Dare’s engineering de­partment that he first considered them for a project.

“I was impressed by the equipment that they offered, but unfortunately, that project fell through,” relates Beauchamp.

Delkor sales manager Fred Sowa says that for the latest project Dare Foods was looking for a new tray former, but that “the actual carton matrix they presented was a bit unique in that they had a large format that ran quite slow and that the other small­er formats required speeds up to 90 cartons per minute.”

Head Start

According to Sowa, the Trayfecta S4 1502 was the best possible solution for Dare Foods, allowing it to utilize two heads for the higher rate, while only one head would be required for the slower rates, a flexibility offered by the machine that is considered to be unique in the business.

“We actually design and manufac­ture three other carton formers, with anoth­er having four heads allowing for forming the 1502 matched so perfectly for this mix of size and rate required, that it was a no-brainer for us to recommend it to Dare Foods,” advises Sowa.

He adds that since Dare required a nominal rate of 78 with a surge rate of 90 cartons per minute for their fastest re­quirement.

Delkor was aware that the speed on these machines is dictated by the car­ton size and style, “But on the 1502, we can mechanically operate at 60 cycles per minute so the machine is not being stressed.”

Key features of the Trayfecta S4 1502 include:

• A tool-less changeover that takes three minutes per head thanks to three ser­vo motors that actually do most of the work automatically;

• Fixed tooling sets that are simple to in­stall, enabling instant startup on the first cycle for immediate formation of quali­ty cartons, with less costly carton waste;

• Changeovers that are easy for opera­tors of all skill levels, via an HMI (hu­man-machine interface), that is very intuitive with easy-to-follow proce­dures;

• Provide a thorough training and support for independent operation by the plant.

• Ability to run three materials: pa­perboard, corrugated and microflute materials with just a minor tooling change.

“You might note that Delkor seems to be a wee bit obsessed with the number three—but when we are talking about the Trayfecta series, it is by design, as it is a play on the word ‘trifecta’, bringing the power of three to the forming applications,” reveals Sowa.

“The Trayfecta can also run three different package formats—cartons, cases and trays, and han­dles glued, locking and fold-over lock designs,” he expands.

“Should you require it, it could form a paperboard carton on one lane, while at the same time form a corrugated case in the other lane,” states Sowa. “It’s just that im­pressive.”

To handle rough going at Dare Foods, the Trayfecta S4 1502 boasts a robust construction with fixture head slide guides that maintains a stroke tolerance with­in 0.008-inches for repeatable and close tolerance motion.

The Trayfecta S4 1502 uti­lizes a Rockwell Automation

Allen-Bradley brand PanelView Plus 700 for easy operator interac­tion, and a ProBlue 7 hot-melt ad­hesive system to seal the cartons, cases and trays, manufactured by Nordson Corporation.

Now using the Trayfecta S4 1502 for cartoning of the Melba toast products, and the new Sweet Thins and Morning Thins products, Beauchamp is quite happy with the whole project.

“Everything worked out very well,” he begins. “The machine was up and running in no time, and it passed all the SAT (site accep­tance test) and commissioning at a 99.5 per cent efficiency.

“We went from a two-hour changeover that took another two hours to fine-tune in production with our old machine, to a less than 10-minute changeover that generat­ed perfect cartons in the first cycle after startup,” recalls Beauchamp.

Sowa concurs, noting that Delkor performed substantial testing prior to the customer’s factory accep­tance test.

“Once their team arrived, we followed Dare’s extensive protocol to prove the machine,” says Sowa.

Beauchamp says he was also happy about the fairly simple training for Dare Foods’ operators.

“After only about 12 hours of training, a new operator could run and perform changeover with the Trayfecta within the required time,” Beauchamp says, noting that Delkor’s assembly technicians also serve as the installation service support.

“As such, when we do our ex­tensive training with the customer in our facility, and follow through at the installation with the same technicians, we can provide a training service that is perfectly in tune with people who are familiar with not only the tray for­mer, but also Dare’s requirements,” re­lates Sowa.