Quality and Reliability Key to Sealer Success at Fish Processor
14 September 2006
An Ishida QX775 tray sealer at leading fish processor Aquascot Ltd has achieved a payback of less than 12 months while delivering the high quality standards demanded by the customer.
Aquascot supplies fresh salmon, organic salmon and trout exclusively to Waitrose. The retailer's continuing success and growth are firmly based on the outstanding quality of its products and this is therefore fundamental to Aquascot's own business approach and to its dealings with its suppliers.
As Charlie Bullock, Aquascot's operations director explains: "There are four key criteria for our suppliers to meet - quality, quality, quality and service.
"For our products, the best quality packaging is that which is practically invisible," he continues. "The product is the most important thing to present to the consumer and this will only happen if the packaging is absolutely right. If it's not up to standard, people notice; if it is, they see the product. For this reason, we fill into pre-formed trays, and similarly we need a sealing system that is able show off the fish to its best advantage. In this respect, the QX775 was the ideal choice."
A major benefit of the Ishida tray sealer is its unique 'Inside Cut' technology. This ensures that no film extends beyond the tray edges, thus maximising pack appearance as well as reducing film consumption by up to 5%. In addition, since film cutting takes place away from the product, any potential damage to either the product or the knives is minimised.
As well as ensuring excellent product presentation, Aquascot also needed a fast and reliable sealing system to deal with increasing demand from Waitrose for its pre-packed product. Traditionally, counter sales have accounted for 75% of Aquascot's supplies to Waitrose, but more recently the balance between these and pre-packed 'convenience' trays has been much more even, with top seal trays continuing to show phenomenal growth.
The QX775 is currently running at around 36 packs per minute, well within its capabilities and governed only by the speed at which the packs can be filled. It replaced two sealers, which between them could only operate at 20 packs per minute.
"Reliability was another important consideration for this equipment," states Mr Bullock. "To date, we have hardly lost any production through downtime. Equally important, the machine is easy to use and changeovers between different trays can be carried out in minutes."
Aquascot has ambitious plans to continue to grow and develop its business with Waitrose. Its on-going investment programme has seen the installation of a range of processing equipment, including de-heading, filleting and portioning machines, and the company is now focusing on the packing side of its operation.
Already this has led to the recent acquisition of another QX775 from Ishida, initially as a back-up contingency, but the company anticipates that the new model will soon form part of a second dedicated line.
"We are still a relatively small business; capital expenditure has to have a proper justification, and of course like everyone else we look for value for money in all our investments," says Mr Bullock.
"However, we would never seek to reduce cost if quality is compromised. The Ishida equipment may not be the cheapest available but I am a firm believer that you get what you pay for.
"What's more when you look at the figures, there is no debate. We would normally hope to see payback on major equipment over two years but in terms of improved efficiency and reliability, the QX775 paid for itself within a year, while delivering the necessary quality vital to the continued success of our business."
