"collaborating with bilwinco on the innovative stamping tool has allowed us to redeploy staff to more critical tasks, minimize waste, optimize packaging, and improve space utilization.
the success of this project has exceeded our expectations, and we are eager to implement the tool in another production line. bilwinco’s dedication to innovation and collaboration has been key to our achievements."
about danish crown
5,620 Danish farmers own the Danish Crown group, which contributes to 49 billion meals for consumers worldwide annually. The group is the world’s largest pork exporter and Europe’s largest producer of pork and meat products.
Founded in 2003, the subsidiary in Svenstrup, North Jutland, has shown impressive growth, solidifying the group’s position as the European market leader in pepperoni toppings for the pizza industry. Pizza is a favorite fast-food choice in many parts of the world. With pepperoni being a top pizza topping, Danish Crown and its subsidiary, Tulip Food Company, aim to become the preferred supplier to the European pizza industry, continuing their growth by delivering high-quality pizza toppings to customers worldwide.
At Danish Crown approximately 20,000 tons of pizza topping are produced annually.
They have successfully been operating three Bilwinco Multihead weighers for years.
The system is used to portion and package sliced pepperoni into trays in different formats.
Due to increased focus on efficiency, a more flexible solution was required to optimize production reducing waste and packaging.
1 An innovative stamping tool customized and developed closely with the Danish Crown Team.
2 Danish Crown in Svenstrup has successfully been operating three Bilwinco Multihead weighers for years.
the challenge
Danish Crown faced several operational challenges in their production lines. Despite already operating three Bilwinco Multihead Weighers to ensure precise portioning, the company sought further efficiency and waste reduction improvements. Inefficient use of packaging materials increases costs and has an environmental impact. A significant amount of employee time was dedicated to manually handling sliced pepperoni, limiting their ability to perform other tasks. Danish Crown, therefore, teamed up with Bilwinco’s technical team to find a solution to optimize the pepperoni pizza topping production with an innovative stamping tool.
the solution
To address these challenges, Bilwinco collaborated with the Danish Crown team to develop an innovative stamping tool as a pilot project. The primary objectives were to minimize waste, optimize food packaging, and improve overall transportation efficiency. This tool was designed to ensure that pepperoni slices fit perfectly into their packaging, streamlining the packing process and reducing the need for manual adjustments. By accurately stamping pepperoni slices, the tool reduces the excess and ensures uniformity, making the slices fit more efficiently into the packaging. This results in reduced material usage, improved storage and transportation logistics, better space utilization, and lower shipping costs.
the results
roi less than one year
This rapid ROI was primarily driven by the newfound operational efficiency, which freed up the equivalent of two to three full-time positions within the production facility.
optimization
Efficiency, less waste and packaging.
conclusion
The pilot project proved to be a resounding success, delivering remarkable results. The precision stamping tool keeps pepperoni waste and material usage at a minimum, contributing to cost savings and environmental benefits. With more uniform and efficiently packed slices, transportation logistics improved, allowing for better space utilization and reduced shipping costs. An employee was redeployed to other critical tasks by automating the process, increasing overall productivity.
The successful implementation of the stamping tool in Danish Crown’s production line underscores the value of innovation and collaboration. The project met and exceeded its goals, demonstrating significant improvements in waste reduction, packaging optimization, and labour efficiency. Encouraged by the pilot project’s success, Danish Crown is now preparing to order the stamping tool for another production line, marking a significant step towards enhanced operational efficiency and sustainability.
Bilwinco remains committed to supporting the Danish Crown’s pursuit of excellence, continually seeking innovative solutions to meet its evolving needs.
