Case Study

Bluebird Foods Flow Wrapped 6 Packs

Case Study

Bluebird Foods Flow Wrapped 6 Packs

“The first challenge was to find the right equipment solution that would fit the space constraints of the factory and meet the physical needs of the people working in it”.

TEG spearheaded a packaging project for Bluebird to introduce flow-wrapped 6 packs, replacing the loose bag 10 and 12 packs of their most popular products. This initiative aimed to enhance shelf presence and affordability in supermarkets, revitalising a stagnant market segment. This project showcases TEG’s innovative approach and proactive mindset in meeting customer needs.

Client Information

Bluebird Foods is the largest manufacturer of snacks and chips in New Zealand, making a range of recognisable products including Bluebird Originals, Copper Kettle, Doritos, Burger Rings, Twisties and Cheezels. Bluebird Foods is a New Zealand based subsidiary of PepsiCo, who operate globally.

Goal

A packaging project to introduce flow wrapped 6 packs replacing loose bag 10 and 12 packs of Bluebird’s most popular products. The goal was to improve supermarket shelf presence and affordability to rejuvenate what had become a static market segment. A secondary goal was to improve line efficiencies through the introduction of the latest high speed, fully automated packing equipment.

Why TEG Projects

TEG Projects have been the project management partner of choice at Bluebird for many years and have a proven track record of consistently delivering quality projects on time, on budget and to the highest quality.

TEG Project Managers have the right skills and know-how to work in complex FMCG environments. Many have held previous management roles working directly for companies like Bluebird and have a wealth of knowledge about what works well and what does not.

This project needed to be delivered on time to meet a strict launch window that was 4 months before the main automation equipment could be sourced from Europe. By working closely with the customer, an interim method of producing the product was found and the launch date was successfully met.

This was an example of how TEG uses innovative thinking and a can-do attitude to deliver the needs of its customers. With a proven track record, it was an easy choice for Bluebird to once again trust TEG with the delivery of this important project.

Solution

In addition to purchasing new equipment, Bluebird also decided to take the opportunity to upgrade internal building fabric replacing walls, ceilings, lighting, and floor coatings prior to the equipment install. This meant carrying out potentially disruptive building works alongside live production – a situation TEG is well versed in managing, and was completed with zero incidents or complaints.

The machinery consisted of automated high-speed packet handling and sorting equipment running at 360 bags per minute, with robotic pick and place of individual packets into the infeed chain of a horizontal flow wrapper, then automated case packing and sealing. The entire line can be operated by one person.

Challenges

The first challenge was to find the right equipment solution that would fit the space constraints of the factory and meet the physical needs of the people working in it. With the help of TEG, and by working closely with stakeholders including factory operators, a solution was found that was both technically and physically excellent.

Much of the project planning and physical build was conducted during Covid 19 disruptions. This meant that traditional project activities such as Factory Acceptance Testing was impossible to conduct in person. Once again innovation played a significant role and FAT was successfully completed using remote technologies and an attitude of mutual willingness by suppliers to ensure Bluebird’s needs would be met.

Results

The results exceed Bluebird’s expectations and the line to this day runs efficiently and without fuss. The decision to upgrade the building fabric was a good one and provided a significant lift to the overall look and feel of the installation, making the area easy to maintain and work in.

Capabilities

Bluebird Foods Flow Wrapped 6 Packs