Agro Tech Foods Ltd, a leading snack manufacturer known for Act II popcorn, faced growing demand for consistent quality and high-speed packaging. Their production lines handled large volumes of popcorn, nuts, and other snack items, making accuracy and efficiency critical.
Production Challenges
Before upgrading, the client struggled with inconsistent fill weights, frequent product giveaway, and limited throughput. Manual adjustments and older weighing equipment could not maintain the precision required for premium snack packaging, leading to higher material costs and lower line efficiency.
Solution
SmartFill deployed the Essentia Multihead Weigher, designed for high-speed, high-accuracy packaging. The Essentia series combines advanced combination logic, precise load cells, and intelligent control algorithms to optimize each fill. Its hygienic SS304 construction and tool-free bucket and tray removal made it ideal for food-grade operations.
Implementation
The installation involved on-site setup, trial runs, and parameter tuning tailored to popcorn and other snack products. Operators were trained to use the intuitive control panel and optional reject systems to minimize off-weight packs. The system was integrated with existing VFFS packaging machines for seamless operation.
Results
After deployment, Agro Tech Foods Ltd reported:
- Throughput increase of 20–25% per line
- Significant reduction in product giveaway
- Consistently accurate fills, meeting premium snack quality standards
- Lower material waste and improved operational efficiency
Key Takeaways
Brands can maximize ROI by investing in precision weighing technology like SmartFill Essentia Multihead Weighers. The combination of speed, accuracy, and hygiene-focused design ensures reduced giveaway, higher throughput, and long-term cost savings.
