Geschreven door Bjorn Hutgens, Manager sales
Geschatte leestijd: 5 minuten
Increasing production capacity does not automatically mean adding more operators. In many food production lines, the real limitation is the way individual process steps work together. Products wait between machines, operators perform repetitive handling tasks or one slower process limits the output of the entire line. Before adding labour, it therefore makes sense to look at where capacity is actually being lost.
Find the bottleneck before adding capacity
Food production is sensitive to variation. Product size, weight and quality can change, while output needs to remain consistent. At the same time, weighing, handling, packing and transport all influence each other. A delay at one station can quickly affect everything downstream.
That is why increasing line capacity starts with understanding the complete process. Where does product accumulate? Which manual activities determine the pace? How much time is lost during changeovers or short stops? And is the theoretical machine capacity actually being used?
Typical opportunities include:
- Automating repetitive product handling
- Synchronising weighing and packing equipment
- Reducing manual transport between process steps
- Automating labelling, inspection and reject handling
- Improving product flow with the right conveyor system
- Identifying recurring downtime and performance losses
Connect the line instead of optimising isolated machines
A faster packing machine has limited value if operators cannot supply it consistently. The same applies to a conveyor running at high speed when the next station regularly stops.
Effective food production automation therefore focuses on the flow between machines. ARCO integrates handling, weighing, packaging automation, labelling and conveying into one connected process. When these steps are properly synchronised, products move through the line with fewer interruptions and less manual intervention. That creates room for higher output without automatically increasing staffing levels.
End-of-line automation can play an important role here. Activities such as weighing, checking, labelling, transporting and preparing products for outbound can often be incorporated into the automated flow instead of relying on operators to move or check products manually.
Use data to recover hidden capacity
Physical automation is only part of the equation. A line may appear to be running well while still losing capacity through short stops, uneven workloads or recurring bottlenecks.
KANSI gives operators and team leaders real-time insight into throughput, uptime and performance across the line. It shows where flow slows down and allows performance to be compared between stations, shifts and periods. Instead of relying on observations or assumptions, teams can use actual production data to decide where adjustments will have the greatest impact.
This matters because extra capacity is not always created by installing another machine. Sometimes it comes from reducing waiting time, changing a setpoint or balancing the workload differently.
More output from the line you already have
The question for food producers should therefore not simply be how many extra operators are needed to increase output. A better starting point is: how much more capacity can we get from the existing process?
ARCO Solutions analyses the complete production flow and designs food automation around the required output, product characteristics and existing equipment. By combining mechanics, software and operational data, bottlenecks can be addressed where they actually occur. The result is a production line that uses its available capacity better and is less dependent on additional manual handling.
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“With our 60% annual growth, our old facility soon reached its limits. Thanks to ARCO’s automated logistics process, we now handle 16,000 orders a day and have room to keep expanding.”
“ARCO’s experience in the mushroom industry helps us open new markets worldwide with our LED2D technology. The partnership creates a very unique combination of knowledge and technology.”
“We saw great commitment and determination. ARCO didn’t leave until the system was running. That shared drive made the cooperation truly enjoyable.”
“ARCO delivered an automated solution that integrates seamlessly with our pick line. Their dedicated approach and smooth execution made it a partnership worth repeating.”
‘When you both believe in solutions, great results come naturally.’
‘ARCO has simplified our production process. Thanks to the comprehensive package of services and the customized solutions, ARCO is the ideal supplier for us.’
“Our cooperation with ARCO was excellent. Where we previously relied on manual and labour-intensive processes, we now have a fully automated system that makes our production far more efficient.”
“ARCO responded quickly and showed great creativity in the design and test setups. Our close cooperation made the successful implementation of the new packaging line possible.”
“ARCO is a no-nonsense partner that thinks in practical, affordable solutions. With their expertise, they build strong and efficient intralogistics systems. We look forward to working together again.”
‘ARCO’s weighing line has had a major impact on our production. Our new system cuts product losses by up to 6%. It was a successful project and a rewarding collaboration.’
