Client
Food Packaging Manufacturer
Industry
Snack & Ready-to-Eat Food Manufacturing
Challenge
Inefficient drying of food packaging led to inconsistent drying times, increased energy costs, and frequent product defects during packaging.
Background
A leading food packaging company in the ready-to-eat snack industry was facing significant challenges with its drying process. The company’s conventional drying methods were resulting in uneven moisture removal from the food packaging, which caused inconsistent results in packaging quality. Some packages were under-dried, resulting in moisture retention, while others were over-dried, leading to product brittleness and increased wastage. Additionally, the process was time-consuming and energy-inefficient, leading to high operational costs and low throughput in the packaging line.
To resolve these issues, the company partnered with Nexgen Hygiene Systems and implemented Nexgen’s Air Knife Drying Systems to improve drying efficiency and ensure consistent, high-quality results for its food packaging operations.
Challenges
Uneven Drying
Variations in airflow and temperature resulted in inconsistent moisture removal, leading to poor quality packaging and increased defects.
Increased Energy Costs
The older drying system consumed excessive power and resulted in high utility bills.
Slow Drying Times
Longer drying cycles slowed down the overall production process, leading to inefficient packaging and delays in meeting production goals.
Product Defects
Over-dried packaging became brittle and prone to breakage, while under-dried packages retained moisture, leading to quality issues and packaging failure.
Solution: Nexgen Air Knife Drying Solutions
Nexgen Hygiene Systems supplied their Air Knife Drying Solutions, specifically tailored to meet the needs of food packaging manufacturers. The air knife systems were designed to deliver uniform drying with optimized air flow and precision control to eliminate inefficiencies.
Key Features:
Uniform Air Distribution
Ensures even drying across all packaging, eliminating dry spots and retaining the desired texture of the packaging.
Digital Temperature Control
Allows precise control over drying conditions, ensuring consistent results across all production batches.
Energy-Efficient Design
Reduced power consumption with optimized airflow and insulation, making the process more cost-effective and eco-friendly.
Fast Drying Time
Significantly reduced drying times, increasing throughput and allowing for faster packaging and higher production capacity.
Hygienic Construction
Built with food-grade stainless steel, ensuring compliance with hygiene standards and easy cleaning in food manufacturing environments.
Implementation
- Phase 1 – Process Audit:
Nexgen’s team conducted a detailed audit of the existing drying process, identifying key inefficiencies, inconsistent moisture removal, and energy wastage. Airflow and temperature variations were measured to pinpoint areas for improvement. - Phase 2 – Installation & Calibration:
Nexgen’s Air Knife Drying Solutions were installed into the packaging line, aligned with the existing system. The air knife dryers were calibrated for each type of packaging, ensuring optimal drying times and consistent results for different products. - Phase 3 – Training & Validation:
Nexgen’s team trained operators on how to properly load packaging, monitor drying conditions, and conduct routine maintenance. Post-installation runs were conducted to validate the performance of the new drying system, ensuring that moisture levels were consistent and met packaging requirements.
Results
Consistent Drying Quality
Every batch of food packaging achieved the desired level of dryness, ensuring consistent texture and preventing issues like brittleness or moisture retention.
40% Reduction in Drying Time
The optimized air flow and faster drying cycles increased production throughput, allowing more packages to be processed in less time.
25% Energy Savings
The air knife system’s energy-efficient design reduced power consumption significantly, leading to cost savings on utility bills.
Zero Packaging Defects
No packaging was rejected due to inconsistent drying, as all products were uniformly dried, leading to improved packaging quality and reduced wastage.
Increased Production Capacity
Faster drying times and reduced inefficiencies allowed the company to meet higher production demands, leading to greater capacity utilization and profitability.
Client Testimonial
“The Nexgen Air Knife Drying Solutions have transformed our packaging process. We now have consistent drying across all packaging, and the time and energy savings are significant. Our throughput has increased, and we’ve seen a noticeable improvement in the quality of our packaged products. It’s made a huge difference for us in terms of both efficiency and product consistency.”
– Packaging Manager, Food Packaging Manufacturer
Conclusion
With the implementation of Nexgen’s Air Knife Drying Solutions, the food packaging manufacturer successfully solved its long-standing drying issues. The solution not only improved drying consistency and energy efficiency but also enhanced product quality, reduced defects, and increased production throughput. The brand now operates more efficiently and meets its production goals while ensuring the quality of its packaging.
Want to optimize your packaging process? Reach out to Nexgen Machines to explore how our Air Knife Drying Solutions can improve drying efficiency and elevate your production line.
Note:
For confidentiality reasons, the actual name of our client has not been disclosed in this case study. Instead, we have used the general name “Coastal Foods” to demonstrate the performance of Nexgen’s Air Knife Drying Solutions. This allows us to maintain client privacy while showcasing the impact of Nexgen’s hygiene innovation.