The exceptional quality, accuracy, and consistency delivered by Ishida’s multihead weigher, integrated Total Packing System (iTPS), and DACS checkweigher are empowering start-up crisp brand Simply Roasted to revolutionize the snacking industry.
Simply Roasted crisps are uniquely baked in the company’s state-of-the-art roasting ovens located in Norfolk. The company emphasizes that this roasting method, rather than traditional frying in hot oil, achieves the same crunch and flavor while significantly reducing fat, calories, and salt. Consequently, Simply Roasted crisps are not only featured in several prominent retail outlets but are also being distributed in cafés and shops across various National Health Service (NHS) locations.
Stuart Monk, Simply Roasted’s Managing Director, highlights that building and maintaining consumer trust poses a major challenge for any emerging brand. Thus, the dependable pack quality and outstanding seals provided by Ishida’s INSPIRA snack food bagmaker are crucial for success.
“With a new product, you literally get one chance to put it in front of consumers, so if the bag isn’t sealed properly or has a small leak, then our crisps may become stale and that creates a poor first impression which is unlikely to lead to a repeat purchase,” he stated. “Our investment in Ishida equipment and the consistent quality seals that it delivers has therefore been very important in enabling us to build brand integrity and loyalty.”
Equally important, the enhanced speed and efficiency of the Ishida system have enabled Simply Roasted to overcome several significant challenges since its inception. The war in Ukraine impacted the prices and availability of cooking oil, while soaring inflation and energy costs significantly affected the company’s overall expenses.
“As a new business, we determined that we could not pass these price increases onto our consumers, so we initially had to absorb them,” Stuart explained. “Now, with the Ishida system operating at nearly three times the speed of our previous bagmaker, achieving remarkable accuracy and minimal giveaway, we can pack more product into each package. This improved efficiency has allowed us to recover some of those costs, enabling us to keep our prices steady while many competitors are raising theirs.”
The INSPIRA iTPS features an Ishida CCW-RV 14-head multihead weigher alongside an INSPIRA rotary bagmaker. At Simply Roasted, it efficiently processes two package sizes of 21.5g and 93g across seven flavors, achieving packaging speeds of 80 bags per minute (bpm) for the smaller size and 60 bpm for the larger size – comfortably beneath its maximum capacity of 120 bpm.
Replacing the company’s original bagmaker, which suffered from poor performance and lack of support, the Ishida system has drastically improved operations.
“Pack weight inconsistencies and product trapped in the seals were two of the major issues, and when we experienced problems, it took a very long time for these to be resolved,” remarked Paulius Imbrasas, Simply Roasted’s Operations Manager.
“Both Stuart and I had experience of Ishida in our previous roles, so we knew we could expect exceptional performance and high service levels, including prompt maintenance support and parts availability, as well as training.”
The Ishida CCW-RV multihead weigher delivers accuracy within one gram of target weight. Additionally, the INSPIRA bagmaker features advanced motor and drive technology that enhances positional jaw control during the sealing process, while Ishida’s rotary back seal band technology guarantees superior back seals, contributing to consistent pack quality.
“A key benefit of the Inspira’s seal quality is that film wastage has also been greatly reduced,” added Paulius.
The INSPIRA bagmaker’s HMI touchscreen facilitates quick setup. Changeovers for the same flavor can occur in approximately five minutes. Furthermore, the machine’s open design allows for easy access to all areas, permitting a complete flavor changeover with manual wash-down in roughly an hour, compared to up to three hours with the previous bagmaker.
“With the old machine, we had to do everything manually,” Paulius explained. “With Ishida, you just select the appropriate program, and everything is ready. This saves a lot of time.”
“In terms of maintenance, the system continuously monitors its performance and alerts us when actions are necessary or issues arise, thereby enhancing its reliability.”
The Ishida DACS-GN-SE012 checkweigher performs an essential final pack weight verification in compliance with regulatory and retailer demands. It features an intuitive display for user-friendly operation, alongside a robust construction for efficient service and maintenance access. Additionally, Ishida’s proprietary Anti-Floor-Vibration (AFV) technology enables the checkweigher to maintain top accuracy, even in challenging production environments.
The entire Ishida system also offers valuable future-proofing as production capacity expands. For instance, the INSPIRA rotary bagmaker can operate at 33% higher speeds, while the checkweigher can relay pack weight data back to the bagmaker for process adjustments, further enhancing performance and efficiency – an advantage as Simply Roasted continues to scale its production.
“The Ishida system is the Rolls Royce of bagmakers,” concluded Stuart Monk. “Ultimately, what all its features and benefits have brought us is peace of mind. Whether sending out samples to a retailer or a potential investor, or fulfilling an online order, we can confidently ensure that the packaging is flawless.”
