Food Engineering logo
  • Sign In
  • Create Account
  • Sign Out
  • My Account
  • NEWS
  • PRODUCTS
  • TOPICS
  • EXCLUSIVES
  • MEDIA
  • FOOD MASTER
  • EVENTS
  • RESOURCES
  • EMAGAZINE
  • SIGN UP!
cart
facebook twitter linkedin youtube
  • NEWS
  • Latest Headlines
  • Manufacturing News
  • People & Industry News
  • Plant Openings
  • Recalls
  • Regulatory Watch
  • Supplier News
  • PRODUCTS
  • New Plant Products
  • New Retail Products
  • TOPICS
  • Alternative Protein
  • Automation
  • Cannabis
  • Cleaning | Sanitation
  • Fabulous Food Plants
  • Food Safety
  • Maintenance Strategies
  • OEE
  • Packaging
  • Sustainability
  • More
  • EXCLUSIVES
  • Plant Construction Survey
  • Plant of the Year
  • Sustainable Plant of the Year
  • State of Food Manufacturing
  • Top 100 Food & Beverage Companies
  • MEDIA
  • Podcasts
  • Videos
  • Webinars
  • White Papers
  • EVENTS
  • Food Automation & Manufacturing Symposium and Expo
  • Industry Events
  • RESOURCES
  • eNewsletter
  • Custom Content & Marketing Services
  • FE Store
  • Government Links
  • Industry Associations
  • Market Research
  • Classified Ads
  • EMAGAZINE
  • eMagazine
  • Archive Issue
  • Advertise
Food Engineering logo
search
cart
facebook twitter linkedin youtube
  • Sign In
  • Create Account
  • Sign Out
  • My Account
Food Engineering logo
  • NEWS
    • Latest Headlines
    • Manufacturing News
    • People & Industry News
    • Plant Openings
    • Recalls
    • Regulatory Watch
    • Supplier News
  • PRODUCTS
    • New Plant Products
    • New Retail Products
  • TOPICS
    • Alternative Protein
    • Automation
    • Cannabis
    • Cleaning | Sanitation
    • Fabulous Food Plants
    • Food Safety
    • Maintenance Strategies
    • OEE
    • Packaging
    • Sustainability
    • More
  • EXCLUSIVES
    • Plant Construction Survey
    • Plant of the Year
    • Sustainable Plant of the Year
    • State of Food Manufacturing
    • Top 100 Food & Beverage Companies
  • MEDIA
    • Podcasts
    • Videos
    • Webinars
    • White Papers
  • FOOD MASTER
  • EVENTS
    • Food Automation & Manufacturing Symposium and Expo
    • Industry Events
  • RESOURCES
    • eNewsletter
    • Custom Content & Marketing Services
    • FE Store
    • Government Links
    • Industry Associations
    • Market Research
    • Classified Ads
  • EMAGAZINE
    • eMagazine
    • Archive Issue
    • Advertise
  • SIGN UP!
Dry Processing

Dry Processing Technology

High speed packaging solves production challenges without sacrificing quality

By Casey Laughman
tna robag FX 3ci

By installing a tna robag FX 3ci, Pipers Crisps was able to reduce waste and increase packaging speed from 80 bags per minute to 140.

Photo courtesy of tna

December 23, 2018

UK-based gourmet chip manufacturer Pipers Crisps Ltd. was founded in 2004 by three farmers, who had the goal of producing high-quality potato chips with local potatoes.

Today, its award-winning products, recognized nationally for their unique and bright packaging design, are distributed throughout the UK, as well as exported to Europe and the US. Following a period of growth in the past two years and rising popularity of its products, Pipers Crisps needed to add new packaging lines to its existing packaging fleet to cope with the additional demand. 

The installation of high speed packaging solutions from tna has enabled Pipers Crisps to increase productivity, double packaging speed and reduce waste while maintaining the highest level of product quality through enhanced seal integrity. 


Meeting increased demand 

With existing equipment achieving throughput speeds of only 80 bags per minute (bpm) for its smaller bags, Pipers Crisps needed to substantially increase bagging speed. The premium chip manufacturer opted for two tna robag FX 3ci – vertical, form, fill and seal (VFFS) packaging solutions. These high speed baggers feature the world’s shortest vertical product transfer from the scale to the pack, helping to maximize packaging performance. The new setup allows Pipers Crisps to package a variety of bag sizes at speeds of up to 140 bpm, resulting in a 75 percent increase, in line with the company’s capacity uplift.

Catering for a variety of snacking occasions, the chip manufacturer needed a packaging solution that could switch between two different pack sizes—40 (1.4 oz) and 150 grams (5.3 oz)—of high quality pillow bags, without lengthy changeover times that would slow down or even stop production. With its lightweight formers, unload assist and twin film spindle, the flexibility of the tna robag FX 3ci makes changeovers fast and easy, enabling operators to easily switch from one bag size to another on the same packaging line. 


Assuring quality with superior seal integrity

The Pipers Crisps brand is renowned for its premium positioning. In such a highly competitive market, quality is crucial to help differentiate brands on retail shelves. It was therefore important that the chosen packaging solution could maintain seal integrity and reliably produce high-quality bags that do not compromise the shelf life of the product within it. 

“During the packaging process, pieces of chips can get caught in the bag seal, compromising seal integrity and reducing the shelf life of the product. When this occurs, it can often lead to product rejects and waste,” says Simon Hill, regional sales manager at tna.

With its rotary jaw design and sealing technology that offers improved seal performance at high speeds, the tna robag FX 3ci proved to be the perfect solution. Featuring patented stripper tube closures, the completely integrated packaging system allows for better control of the product through the packaging and filling cycle, therefore helping to control dust generation and minimizing crumbs in the end seal of the bag. 

The tna robag FX 3ci was also customized with product-in-seal-detection (PISD) software that monitors product in the seal and jaw area. If seal integrity is compromised, the system immediately alerts the operator so that bags can be quickly removed from the line for further inspection. That way Pipers Crisps is able to ensure that each bag meets the highest quality standards while keeping waste to an absolute minimum.

“Before the installation, we experienced 3 percent wastage at 80 bpm, as we had to manually detect and remove any bags with compromised end seals or pleats before they entered the packaging area,” says Richard Mottram, factory manager, Pipers Crisps. “Now, our wastage is down to 1 percent at 140 bpm—which has surpassed our expectations. As a result, it has helped us gain better control over product losses and achieve operational cost savings, while contributing to quality assurance.”


For more information, visit  www.tnasolutions.com

KEYWORDS: food packaging technology packaging trends snacks

Share This Story

Looking for a reprint of this article?
From high-res PDFs to custom plaques, order your copy today!

Casey laughman0031

Casey Laughman is the former Editor in Chief of Food Engineering magazine. He has almost two decades’ experience as a writer and editor for mainstream and trade publications. He spent several years as a writer and editor for two news services before becoming the editor of a legal publication and managing editor of a trade magazine that covered the commercial facilities market.

Recommended Content

JOIN TODAY
to unlock your recommendations.

Already have an account? Sign In

  • Global Organic Food & Beverage Market to Grow

    Global Organic Food & Beverage Market to Grow

    With a CAGR of 12.07%, Bonafide Research estimates this...
    People & Industry News
  • skilled MEP worker

    Predicting Food and Beverage Manufacturing Trends for 2024

    The two words that should be kept in mind are labor and...
    Automation
    By: Derrick Teal
  • cleaning and sanitation

    The basics of cleaning and sanitation in food plants

    Sanitation maintains or restores a state of cleanliness...
    Cleaning | Sanitation
    By: Richard F. Stier
Subscribe For Free!
  • eMagazine
  • eNewsletter
  • Online Registration
  • Manage My Preferences
  • Customer Service

OT Cybersecurity Vulnerabilities in Food Manufacturing Facilities

OT Cybersecurity Vulnerabilities in Food Manufacturing Facilities

Understanding Impacts of OT Cybersecurity Events in Food Manufacturing

Understanding Impacts of OT Cybersecurity Events in Food Manufacturing

Food Plant Openings and Expansions April 2025

Food Plant Openings and Expansions April 2025

FA&M 2025 in Rewind

FA&M 2025 in Rewind

More Videos

Popular Stories

Conagra Logo

Conagra Brands to Sell Chef Boyardee Brand to Hometown Food Company

Salt

FDA to Amend Standards of Identity to Include Salt Substitutes

Vilter IHP in plant

Industrial Heat Pumps: Sustainable Energy Solutions for Now and the Future

CHECK OUT OUR NEW ESSENTIAL TOPICS

Alternative ProteinAutomationCleaning/SanitationFabulous Food Plants

Food SafetyMaintenance StrategiesOEE

PackagingSustainability

Events

June 5, 2025

Mass Customization Driving Innovation in the Food and Beverage Industry

The food and beverage industry is at the nexus of transformative global manufacturing trends, driving a shift toward personalized, customer-centric solutions. 

June 5, 2025

How Cafe Spice Uses Automation to Propel Private Label

Learn about Cafe Spice’s new, state-of-the-art, highly automated manufacturing facility in Beacon, New York. 

View All Submit An Event

Products

Recent Advances in Ready-to-Eat Food Technology

Recent Advances in Ready-to-Eat Food Technology

See More Products

Plant of the Year

Related Articles

  • PMMI, Rockwell Automation announce presenters and topics for PACK EXPO International

    Manufacturers meet the demand for new product varieties without sacrificing quality

    See More
  • pet treats

    Production and packaging strategies change as pet food market grows

    See More
  • melanie-lim-246b6c6IeC0-unsplash_1170x658.jpg

    Shifting to Sustainable Packaging—High Reward Without High Risk

    See More

Related Products

See More Products
  • Rice-Engineering-Website-Cover-439x600.jpg

    Advances in Science & Engineering of Rice

See More Products
×

Elevate your expertise in food engineering with unparalleled insights and connections.

Get the latest industry updates tailored your way.

JOIN TODAY!
  • RESOURCES
    • Advertise
    • Contact Us
    • Food Master
    • Store
    • Want More
  • SIGN UP TODAY
    • Create Account
    • eMagazine
    • eNewsletter
    • Customer Service
    • Manage Preferences
  • SERVICES
    • Marketing Services
    • Reprints
    • Market Research
    • List Rental
    • Survey/Respondent Access
  • STAY CONNECTED
    • LinkedIn
    • Facebook
    • YouTube
    • X (Twitter)
  • PRIVACY
    • PRIVACY POLICY
    • TERMS & CONDITIONS
    • DO NOT SELL MY PERSONAL INFORMATION
    • PRIVACY REQUEST
    • ACCESSIBILITY

Copyright ©2025. All Rights Reserved BNP Media.

Design, CMS, Hosting & Web Development :: ePublishing

Food Engineering logo
search
cart
facebook twitter linkedin youtube
  • Sign In
  • Create Account
  • Sign Out
  • My Account
Food Engineering logo
  • NEWS
    • Latest Headlines
    • Manufacturing News
    • People & Industry News
    • Plant Openings
    • Recalls
    • Regulatory Watch
    • Supplier News
  • PRODUCTS
    • New Plant Products
    • New Retail Products
  • TOPICS
    • Alternative Protein
    • Automation
    • Cannabis
    • Cleaning | Sanitation
    • Fabulous Food Plants
    • Food Safety
    • Maintenance Strategies
    • OEE
    • Packaging
    • Sustainability
    • More
  • EXCLUSIVES
    • Plant Construction Survey
    • Plant of the Year
    • Sustainable Plant of the Year
    • State of Food Manufacturing
    • Top 100 Food & Beverage Companies
  • MEDIA
    • Podcasts
    • Videos
    • Webinars
    • White Papers
  • FOOD MASTER
  • EVENTS
    • Food Automation & Manufacturing Symposium and Expo
    • Industry Events
  • RESOURCES
    • eNewsletter
    • Custom Content & Marketing Services
    • FE Store
    • Government Links
    • Industry Associations
    • Market Research
    • Classified Ads
  • EMAGAZINE
    • eMagazine
    • Archive Issue
    • Advertise
  • SIGN UP!