Faster fill speeds help justify packaging change

High-end products demand premium packaging, and the conventional valve bag with a vertical seam down the middle of its back just wasn’t cutting it for Green Mountain Coffee Inc. So in April the Waterbury, Vt.-based roaster began converting more than 60 coffee varieties to a new Corner-Seal bag from Fres-co System USA.

Engineering drove Green Mountain Coffee’s conversion to corner sealed bags, which are filled faster and support better graphics than the bags they replace.


High-end products demand premium packaging, and the conventional valve bag with a vertical seam down the middle of its back just wasn’t cutting it for Green Mountain Coffee Inc. So in April the Waterbury, Vt.-based roaster began converting more than 60 coffee varieties to a new Corner-Seal bag from Fres-co System USA.

Given that the new package is easier to open and supports better graphic presentation, it’s the kind of conversion that typically occurs at the insistence of marketing executives. But engineering drove Green Mountain’s conversion.

“Contrary to popular belief, engineering does come up with some good ideas,” deadpans Paul Comey, vice president of facilities and process engineering. He championed the conversion project, which required the purchase of two GL 14 vertical form/fill/seal machines to replace two older units from Fres-co. The new lines fill about 40 bags a minute, a 42 percent improvement. The f/f/s units also perform a gas flush, a growing trend away from vacuum packaging for upscale grinds and whole-bean coffees.

“Setting up the label application was an integral part of the conversion,” Comey adds. To minimize changeovers, three printed bags are used—green, beige and dark brown—and a blend-specific label is affixed after filling. A “significant upgrade” to the labeling unit makes the process much more precise, he says.

Green Mountain’s retail products are sold in 10- and 12-ounce bags, typically in the $6.50 to $9 range. All four corners of the bags are sealed, helping them retain a squared-off look on store shelves, even after shipping. The composite film is lacquered over a matte finish to distinguish it from the glossy look of other soft-sided valve bags. Once the f/f/s conversion is complete, Comey hopes to reduce film thickness.

For more information:
Chris Burger, Fres-co System USA, 215-721-4600, www.fresco.com

Did you enjoy this article? Click here to subscribe to Food Engineering Magazine.

You must login or register in order to post a comment.

Multimedia

Videos

Image Galleries

Plant of the Year 2015

Mars Chocolate was chosen as Food Engineering’s 2015 Plant of the Year. The first new Mars candy plant in North America in 35 years is not only LEED Gold certified, it’s highly automated as well.

Podcasts

Burns & McDonnell project manager RJ Hope and senior project engineer Justin Hamilton discuss the distinctions between Food Safety and Food Defense as well as the implications for food manufacturers of the Food Safety Modernization Act.
More Podcasts

Food Engineering

Food Engineering April 2015 Cover

2015 April

The April 2014 issue of Food Engineering features the Plant of the Year: Mars Chocolate. The first new Mars chocolate candy plant in North America in 35 years is not only LEED Gold certified, it’s highly automated as well.

Table Of Contents Subscribe

Plant Facility/Site Issues

What issue about your current plant facility/site keeps you up the most at night?
View Results Poll Archive

THE FOOD ENGINEERING STORE

Food-Authentication-Flyer-(.gif
Food Authentication Using Bioorganic Molecules

This text provides critical tools and data needed to augment routine food analysis and enhance food safety by aiding in the detection of counterfeit, and potentially deleterious, foods.

More Products

Clear Seas Research

Clear Seas ResearchWith access to over one million professionals and more than 60 industry-specific publications,Clear Seas Research offers relevant insights from those who know your industry best. Let us customize a market research solution that exceeds your marketing goals.

STAY CONNECTED

FE recent tweets

facebook_40.pngtwitter_40px.pngyoutube_40px.png linkedin_40px.pngGoogle +

Food Master

Food Engineering Food Master 2015Food Master 2015 is now available!

Where the buying process begins in the food and beverage manufacturing market. 

Visit www.foodmaster.com to learn more.