“Braced for the challenges of the future”
The "Wenisch" traditional butcher's business increases productivity with a thermoforming packaging machine from MULTIVAC
Shortages of skilled staff, rising energy costs, climate change: Even for the "Wenisch" butcher's business in the Bavarian town of Straubing, 2023 will be a challenging time. It was for this reason that, when expanding its own in-house manufacturing capacity, this traditional business decided on a R 126 thermoforming packaging machine from MULTIVAC. It is not only energy-efficient, it also saves on packaging material and therefore improves the company's CO₂ balance. Thanks to its intuitive control concept, the machine can even be operated by temporary workers after a short induction period.
In 1952 Anton Wenisch and his wife Auguste started a small butcher's shop in Straubing, which is located about 110 kilometres north-east of Munich. In the opposite direction, some 100 kilometres south-west of the Bavarian capital, Sepp Haggenmüller invented the first chamber machine for packing food in film pouches just nine years later in his garage - and with that he laid the foundations for the MULTIVAC company. Two stories, which were due to overlap 61 years later. MULTIVAC has since become one of the largest packaging specialists in the world with over 80 subsidiaries around the globe. The "Wenisch" family business is now managed by son Stefan Wenisch Junior and his brothers, and the company employs some 150 staff. And not only in the butcher's business but also in a restaurant, a four-star hotel, the ox roasting venue at the "Gäuboden" festival in Straubing, as well as five shops in Straubing and Regensburg. There people can enjoy delicacies such as paprika pork sausages, cutlets, dumplings and the so-called Holy Beef from the family's own Muggenthalter farm. Delicacies, which all come from a central manufacturing facility in Straubing. “Due to increasing demand, we expanded the manufacturing capacity in 2022 by 700 square metres. And we also took the decision to invest in a packaging machine with greater output,” recalls Stefan Wenisch. Up to that point a chamber machine had been used, which had already reached the limits of its capacity. In future there was to be the addition of a thermoforming packaging machine with a greater degree of automation and throughput. “In order to save energy and resources, while at the same time achieving higher productivity, it was important for us to find a machine, which would operate very energy-efficiently and be completely failsafe, as well as being frugal with packaging material and easy to operate. MULTIVAC has been the name in the sector for decades. I got to know the technology during my training as a meat technologist in Kulmbach, and I have always been impressed with it. One thing was always clear: When we get a thermoforming packaging machine, it will be one from MULTIVAC.” The choice was made in favour of the R 126 model, a compact and versatile thermoforming packaging machine for the sector producing handcrafted products.
The R 126 is a "multi talent" in the packaging area at the "Wenisch" production hall. It packs virtually the company's entire product range in flexible film - not only meat and sausage products, but also sauces, soups and dumplings. The process is always identical. The forming station first produces the pack cavities from a PA/PE lower web, using compressed air and vacuum. After the thermoforming process has been completed, the pack cavities then travel into the loading area. There the staff members load the products into the cavities, for example six burgers into one pack cavity. After the loading is complete, a vacuum is created in the sealing station of the R 126, and an upper web is sealed to the pack cavities. This removal of atmosphere from the packs gives the products a longer shelf life. As an option, it is possible to have a modified atmosphere pack (MAP), where the machine replaces the air with a gas mixture of carbon dioxide and nitrogen, which is tailored to the particular product. The next stage is the severing of the individual packs from the strip of packs in the web by means of cross cutting and longitudinal cutting units. The individual packs then travel on a transport conveyor and land in a container. Ready to be transported to the point of sale. “Thanks to the R 126, we can pack virtually our entire product range, while saving time and being very gentle on the product. Significantly faster than was possible before with the chamber machine,” says Stefan Wenisch.
Energy-efficient electric motors reduce energy consumption
In times of rising energy prices, the energy efficiency of machines and lines is an important criterion, when making an investment decision. “MULTIVAC was able to convince us with their resource-saving technology,” says Stefan Wenisch. Energy-efficient electric motors are used on the R 126 for the most important energy consumers - the lifting units for the forming, sealing and cutting stations. “Compared with the classic pneumatic drives, it is possible to reduce the energy consumption significantly in these areas,” says Martin Dattler, Regional Sales Manager at MULTIVAC. The thermoforming packaging machine also has a power-saving standby function for pause times, which can be activated and deactivated without a long transition period. In addition to this, "Wenisch" has also succeeded in saving packaging material with the R 126. Whereas in the past there was always pouch trim left behind, when the chamber machine was being used, material usage has now been optimised with the R 126. The benefits are clear: "Wenisch" saves material costs, reduces waste and at the same time improves its environmental balance.
“Ease of operation is a great relief for us”
It was not just the compact design of the machine or the energy and resource efficiency, which were crucial for "Wenisch", when deciding on the MULTIVAC R 126 for their future packaging requirements. The machine also had to be easy and reliable to operate without a long induction period. Since the corona pandemic struck, the sickness absence rate has become an ever more significant competitive factor. If only one specialist were able to operate the R 126, his absence would immediately have a very negative effect on the company's productivity. MULTIVAC is also aware of that. MULTIVAC has therefore developed the HMI 2.0 control terminal, which guides staff members through the operation of the machine, using intuitive clear text, graphics and help functions. “Our staff do not need any programming knowledge and can operate the machine reliably after a short induction period,” emphasizes Stefan Wenisch. “This ease of operation is a great relief for us.” It also leads to shorter downtime.
Rapid-reaction service for less downtime and high productivity
Stefan Wenisch is impressed not only with the machine itself, but also with the level of service. “Experienced technicians from MULTIVAC were at our side from the start of the installation, when putting the machine into service,” says Stefan Wenisch. “They trained our staff members and carried out safety instruction, so that we were able to start operating the machine very quickly.” And the company also benefits in everyday operation from the locally based regional service technicians and their rapid reaction time. Experts at MULTIVAC are also available on the phone. If "Wenisch" is running a new product on the machine, these service technicians are able to accelerate the introduction process with tips, tricks and suitable presettings. And in the worst case scenario, a service technician can be on site within an hour. The rapid supply of spare parts is also guaranteed. Should a component on the thermoforming packaging machine break down, a courier driver can quickly be on the way with the spare part. The component can be replaced within half a day at the latest. “This speed of reaction helps us to minimise any downtime and increase our productivity. It is really great to be able to work with such a fantastic machine in our brand new production setting,” says Stefan Wenisch in conclusion. “With the R 126 we have found a packaging solution, which enables us to feel braced for the challenges of the future.”
06.09.2023
