Private Labeler Needs Flexibility, Reliability and Support

This pretzel and snack producer puts machines through their paces to determine flexibility and reliability.

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As a private label food manufacturer, Pretzels, Inc. supplies high-quality baked snacks to well-known labels and store brands alike across the U.S. and into Europe. With so many customers, the company needs to react to changes in the market and adapt to various different brands on a daily, and sometimes hourly, basis. This unique requirement has a big impact on the packaging and processing equipment the company selects.

In an unfortunate turn of events, the Pretzels, Inc. Peanut Butter Pretzel facility in Canonsburg, Pa., burned to the ground in January 2016. If there was a silver lining to the situation, Paul Schaum, COO, found himself with the unusual task of equipping a new facility, practically from scratch. This meant specifying an all-new line without the burden of any legacy pieces. But with more than 35 years working with packaging and processing equipment, Schaum wasn’t going in without a few preconceived ideas of what he would be looking for in OEM partners. PP-OEM talked to him about Pretzels Inc. and its unique set of machinery needs.

PP-OEM: What are you looking for in an OEM supplier?
What I’m looking for is a well-rounded supplier who can not only deliver me the initial machine, but be able to supply me with parts when needed instead of making us shut down for weeks while waiting for spare parts to be made. I’m also looking for proven reliability of equipment so that my uptime is maintained. But perhaps most uniquely to our business, I’m looking for quick changeovers because we’re a copacker and private labeler with multiple customers. We’re not making pretzels and snacks for one brand, we’re creating them for dozens. So, we have to be able to move from one style of film to another, and be able to make some rather quick changes on back-seal and jaw temperatures, for instance, and be back up and running. Because in a lot of cases, the same product is just going into different packaging.

PP-OEM: For the quick changeover piece, how do you go into vetting equipment to be sure it’s ideal for short runs of many dozens of different films or package formats?
We use a fairly standard package when we go out to look at equipment. We have specific speeds and changeover capabilities that we seek out. We look for quick and safe former changes, and for factors that make it easier for an operator to get in and out of a piece of equipment so that they can run their film through in a simple fashion. We ask, “How do we do a film change from one type to another in different sizes? How do we tackle that quickly and effectively?”

Also, we look at every piece of equipment available. We look at them, specifically, for uptime and downtime pieces for different equipment that we have now. We have a wide variety of equipment and we can plot its reliability and talk to machine manufacturers about issues that we’ve had. We ask the questions, what have they done in the last five years since we purchased one of their pieces of equipment to alleviate some of the issues that we currently have on an older piece of equipment? Have they upgraded?

We look at the new tolerances, we look at the new food safety pieces that we have and see if they are up to date with those requirements, or what it will take to get a piece of equipment that’s proven reliable to fit the new food safety requirements. So those are the factors that we investigate and vet—there’s quite a bit of that that goes on. 

PP-OEM: Once you’ve narrowed down your choices to select a machine, do you do an FAT? SAT?
We have a standard factory acceptance test now, following the guidelines that came out of PMMI and OpX for factory acceptance tests. In some cases, we actually will go in and do a full test. In other cases, where we have a known supplier and a known piece of equipment and it has a specific history, we will actually shorten that test because it’s already been proven and we’re just getting another copy. But we do look at any changes to that format that, say, a checkweigher or auger filler has gone through to adapt to the new rules—we’ll look at those pieces specifically.

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