Ready Meal Line

A major food company in the UK desired to reduce unit cost and improve packing rate using automation for one of their sites. This was particularly challenging due to the number of SKUs and small run sizes. Typical automated ready meal lines are designed for high volume SKUs so that changeover time for an automated line does not cause an unacceptable level of efficiency losses.

We needed a different approach. We developed a specification for a line that would be flexible enough to handle over 35 SKUs and would allow 30 mins changeover time. This approach was challenging the norm due to the amount of ingredients involved in the 35 SKUS. Ingredients included different types of protein, pasta, vegetables and cheeses. We worked with all major OEMs of ready meal lines in Europe and went through 3 months of trials to identify the right solution.

We engaged site operations, technical, procurement and engineering teams during trials to ensure everyone agreed with the equipment selection.

The end result was the design of a complete ready meal line with help from OEMs, and presenting our business case financial calculations for capital sanction approval. The project was put on hold due to Covid-19 but all works were completed using detailed URS and tender process.