Sai Foods Ltd is an expanding UK food manufacturer specialising in fresh snack goods for the food-to-go sector. Their core product range includes filled subs, ciabattas, sandwiches, and wraps.
Prior to our consultation, Sai Foods relied entirely on a manual bagging process. This highly repetitive, manual approach created severe production bottlenecks at the end of the line. Furthermore, hand-wrapping resulted in inconsistent packaging seals, which left products vulnerable to moisture and air ingress, limiting their overall shelf life. These operational constraints restricted the client from taking on larger wholesale orders and scaling their business effectively.
Record Packaging Systems Ltd specified, supplied, and fully integrated a Record Sparrow horizontal flow wrapper into the client’s existing production line. We selected the Sparrow model specifically for its compact footprint, making it ideal for production floors where space is at a premium. The machine features an easy-to-clean stainless steel design built to UK food hygiene standards and offers quick-changeover capabilities, allowing the client to transition seamlessly between different product sizes.
Our technical engineering team managed the complete installation and integration. To ensure a smooth handover, we delivered a comprehensive training programme for the Sai Foods staff. This essential onboarding covered safe machine operation, film loading procedures, and routine maintenance protocols, ensuring operators were fully competent before production resumed.
By transitioning from manual bagging to an automated flow wrapper, Sai Foods achieved all key project objectives:
Increased Output: Packaging speeds instantly scaled up to a continuous, automated rate of over 60 packs per minute, eliminating previous production bottlenecks.
Extended Shelf Life: The precision engineering of the Record Sparrow ensures a consistent, airtight seal on every pack. This protects the fresh goods from moisture and air, significantly improving product longevity and wholesale viability.
Optimised Labour Allocation: Automating the packaging stage completely removed the need for manual wrapping. The client successfully reduced labour costs in the packing area and reallocated staff to core food preparation tasks.
Enhanced Presentation: The final products now feature a uniform, professional, and retail-ready finish that meets the strict presentation requirements of commercial retailers across the UK.
