Frito-Lay, a division of PepsiCo, has been a global leader in the snack chip industry for over 75 years. With brands accounting for 40% of the global snack chip market, Frito-Lay continues to set the standard for quality and innovation. In Central and Eastern Europe, their presence has grown steadily since establishing their first plant in Poland in 1993.
By 2008, Frito-Lay sought to modernise and improve production efficiency at their plants in Grodzisk Mazowiecki and Tomaszów Mazowiecki. Kenray Global was brought on board to deliver advanced forming sets that would enhance performance, improve bag quality, and support Frito-Lay’s commitment to excellence.
The Challenge
With the growing demand for snack products in Poland and across the region, Frito-Lay needed to optimise their production lines for speed and accuracy while maintaining their high-quality standards. To achieve this, they required forming sets that would integrate seamlessly with their existing machines and deliver consistent, superior results at high speeds.
Collaborative Solutions
Kenray worked closely with Frito-Lay and their OEM to develop forming sets tailored to their specific needs. This collaboration leveraged Kenray’s extensive experience in the snack sector and focused on:
- Improving Efficiency: High-speed forming sets were designed to handle production speeds of up to 170 bags per minute.
- Enhancing Product Flow: Adjustments were made to ensure smooth, consistent product flow through the forming sets.
- Optimising Bag Quality: Superior film control was achieved, leading to better bag presentation and end seals.
Kenray’s in-house design, cutting, and assembly processes ensured that all formers were manufactured with precision and delivered within tight timeframes. Rigorous testing on bagging machines in Kenray’s service area guaranteed consistent performance before deployment.
Results and Benefits
The implementation of Kenray’s forming sets delivered measurable improvements across Frito-Lay’s production lines, including:
- Higher Speeds: Packing speeds reached up to 170 bags per minute, significantly boosting output.
- Reduced Downtime: Enhanced product flow minimised disruptions, improving overall efficiency.
- Cost Savings: Improved film control reduced material waste and operating costs.
- Exceptional Bag Quality: The combination of precision engineering and advanced film handling produced bags that exceeded Frito-Lay’s high standards.
Long-Term Success
Frito-Lay has continued to rely on Kenray’s expertise for ongoing support and innovation. By using Kenray’s specialist consultancy service, K-Plan, the company ensures their forming sets are properly maintained, achieving maximum efficiency and extending the lifespan of critical components.
This long-standing partnership highlights the value of collaboration and a shared commitment to quality, efficiency, and innovation. Kenray remains dedicated to exceeding Frito-Lay’s expectations and supporting their success in the ever-evolving snack market.
