Glenhaven, based in Wicklow, Ireland, is a leading producer of high-quality frozen chicken products. Serving both retail and food service sectors, they are known for their commitment to quality and innovation in the frozen poultry market.
Glenhaven faced a significant logistical bottleneck involving mixed-product cases (e.g., 12 southern fried chicken pieces and 12 nuggets). Their existing process was highly manual and inefficient:
Double Handling: Staff had to half-fill a case with one product, palletise it, and store it in the freezer overnight.
Storage Constraints: The following day, boxes had to be removed from the freezer to be finished with the second product.
Labour Intensive: The process required multiple manual interventions and significant floor space for temporary storage.
Record Packaging designed and installed a comprehensive, end-to-end automated line valued at over €800,000. This bespoke system allowed for a sophisticated “buffer and blend” approach.
Key components of the solution included:
Processing & Packing: A twin-lane multihead weigher paired with two VFFS (Vertical Form Fill Seal) machines.
Smart Conveying: A complex network of T-shaped and bypass conveyors with automated controls.
Automation: Dolav tippers and a case erector integrated with a carousel system.
End-of-Line: Metal detector/checkweigher combinations, a case taper, and a fully automated palletiser.
The system allows one product to be run and automatically diverted into Dolavs. When the second product is run, the bypass conveyor delivers it to operators who fill the first half of the box, while the Dolav tippers present the stored product to complete the second half of the case in a continuous flow.
The installation transformed Glenhaven’s production efficiency and bottom line:
Zero Overnight Storage: The need for intermediate freezing and overnight storage of half-filled boxes was completely eliminated.
Drastic Labour Reduction: The line now requires only one operator (a forklift driver), significantly reducing overheads.
Increased Throughput: By removing double handling, the facility has achieved much higher daily efficiencies.
Space Optimisation: Valuable freezer and floor space previously used for “work in progress” has been reclaimed for finished stock.
