Campbells Soups

New equipment increases Campbell’s production by 30%

Production at Campbell’s Grocery Products in Worksop has increased by approximately 30%, thanks in part to new machinery designed by hoisting and tipping manufacturers, Base Handling Products Limited. The seven machines have been a key factor in the re-launch of the entire Homepride cook-in-sauce range, completely transforming the production process.

Manufacturing various soups and sauces involves the loading and mixing of many different ingredients; from vegetables and meat, to herbs and spices. Before the new equipment was introduced, there were various restrictions with this process. Previously only defrosted ingredients could be handled. This meant that all ingredients had to be defrosted before production. The new machinery allows frozen materials to be used, which speeds up the production process. There were also problems involved with the double handling of materials and damage to delicate ingredients.

David Presho, Sauces Technical Manager at Campbell’s, wanted to purchase new machinery that would eliminate these restrictions and allow them to increase production. In order for the new machinery to increase the number of batches produced per hour and allow a wider variety of ingredients to be used, it had to speed up the loading time of each batch processed. The time limit Campbell’s gave Base for the loading process was short, so Base had to design bespoke hoisting and tipping equipment that would effectively meet Campbell’s quota.

The main ingredient in most recipes is frozen vegetables which are supplied in 1000 Kgs cardboard Octoboxes. These boxes are loaded directly into Double Pillar Tippers using a powered hand pallet truck and tipped into the cooking vessel. The design of the tipper and its interface with the cooking vessel are such that 100% of the products are delivered into the vessels with no spillage.

Most other ingredients are loaded into Stainless Steel Octobins that mimic the cardboard Octoboxes and can therefore be lifted and tipped using the same Double Pillar Tippers. In the case of the tinned products, they were first decanted into 200 Litre tote bins and then tipped into the Octobins using a Single Pillar Mechanical Bin Tipper.

Finally, the high value and taste sensitive ingredients are added to the Octobins from a special purpose IBC platform and weighing system. A maximum of three 1 Ton IBC’s can be mounted on the platform and the contents can be discharged directly into the Octobin which is placed on a mobile weighing platform directly underneath. The ingredients from the IBC’s can be accurately metered out according to the recipe requirements ensuring consistency of product quality and taste.

Finally, the high value and taste sensitive ingredients are added to the Octobins from a special purpose IBC platform and weighing system. A maximum of three 1 Ton IBC’s can be mounted on the platform and the contents can be discharged directly into the Octobin which is placed on a mobile weighing platform directly underneath. The ingredients from the IBC’s can be accurately metered out according to the recipe requirements ensuring consistency of product quality and taste.

Finally, at the end of each batch run or production shift, all equipment must be hygienically cleaned to a very high standard. The Stainless Steel Octobins, being so large and unwieldy, presented a further manual handling hazard. To solve this problem, Base designed and supplied their unique pneumatic tipper. This machine is used to tip the empty Octobin towards the hygiene operator so that it can be washed out using a high pressure hose.

Since the new machinery has been installed, a wider selection of materials can now be used and there is no worry of damage to delicate ingredients, due to the need for manual handling of ingredients being cut. Batch cycle times have decreased, allowing production volumes to increase in the region of 30%.

Health & Safety considerations are extremely important to both Campbell’s and Base, so it was essential that the machinery met strict legislation effectively. The equipment has greatly reduced manual handling, resulting in a much safer working environment. All equipment supplied is guarded to PD5304:2000 Safety of Machinery Specification.

Campbell’s Grocery Products, now Premier Foods has become one of world’s leading food companies. During the past ten years, they have acquired popular food brands such as Homepride, Batchelors and Oxo. It is specifically the re-launch of the Homepride cook-in-sauce range that the new equipment has been vital to. As a result of the acquisitions, the UK business is now the largest in Europe, with a turnover of over £250 million.

Mr Presho commented on Base’s professional approach and willingness to implement Campbell’s own suggestions in the machinery design. He said, ‘we would not hesitate to use Base again or to recommend them to other parts of the business.’

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