Ulma Packaging, a leading provider of food packaging solutions, recently collaborated with Moo Free, a dairy-free and vegan chocolate supplier based in Devon, UK. This partnership resulted in Moo Free upgrading its packaging machinery by incorporating Ulma’s FR 200 flow pack wrapper (HFFS).
Moo Free, known for its commitment to sustainability and meeting the needs of vegan and vegetarian customers, made a strategic investment in Ulma’s cutting-edge HFFS technology. This decision aimed at enhancing productivity while maintaining sustainable practices in the production of their dairy-free, wheat-free, gluten-free, and soya-free chocolates.
The company’s dedication to sustainability is evident in its use of non-single-use plastics, recycled materials, and paper, enabling them to achieve zero waste to landfill. However, the need for a new packaging solution arose when Moo Free’s existing machine, after years of continuous use, started experiencing performance issues. The outdated machinery struggled to efficiently wrap the desired amount of chocolate, resulting in production delays and wastage. Additionally, sourcing replacement parts for the ageing equipment became increasingly challenging.
Marcus Woods, Moo Free’s operations manager, emphasized the vital role of packaging machinery in their daily operations. However, the existing machine could no longer keep up with their production demands, frequently causing disruptions and wastage due to variable performance and film alignment issues.
After thorough research and considering their sustainability-focused requirements, Moo Free reached out to Ulma Packaging for a potential solution. Having heard positive feedback through word-of-mouth, Moo Free had confidence in Ulma’s ability to address their specific needs.
Ulma Packaging recommended the FR 200 horizontal flow pack wrapper, perfectly suited to Moo Free’s product range and sustainability objectives. The FR 200 resolved film alignment issues through its motorized unwind on the film reel holder, easy-to-thread double adjustable folding box, and three pairs of rollers for longitudinal film pulling and sealing. This innovative design significantly reduced waste and downtime.
Another crucial aspect of the new packaging solution was ensuring strict sanitizing and safety measures to prevent cross-contamination in the food industry. The FR 200’s cantilever construction allowed easy access for routine sanitation and cleaning, maintaining the integrity of the products. Additionally, the machine’s 7″ touch-screen human-machine interface (HMI) facilitated quick parameter adjustments to accommodate Moo Free’s diverse product sizes and shapes.
The installation process was seamless, with Moo Free conducting test runs at Ulma’s Sheffield headquarters to ensure compatibility with their chocolates and sustainable packaging materials. Woods commended Ulma’s efficient installation team, which minimized downtime during the transition.
“The FR 200 has transformed our production process, and Ulma’s exceptional service and support have been invaluable,” added Woods. “We are already reaping the benefits of this flow pack wrapper, and I wouldn’t hesitate to return to Ulma for future packaging machinery needs.”
Since implementing the FR 200, Moo Free has witnessed a significant increase in productivity. The new machine achieves up to 110 packs per minute (ppm), a remarkable improvement compared to the previous peak rate of 36 ppm. The elimination of film alignment issues and reduced downtime have further enhanced production efficiency.
“We are delighted to have partnered with Moo Free to provide them with our FR 200 flow pack wrapper. It is incredibly rewarding to see how our packaging solution has contributed to improving both their productivity and sustainability efforts. At Ulma Packaging, we take pride in offering innovative machinery that meets the specific needs of our customers, and we are thrilled to have played a part in enhancing Moo Free’s production process,” concluded James Couldwell, Ulma Packaging’s managing director.
