Global supplier of integrated food processing and packaging solutions, tna Solutions, has partnered with Mister Bee Potato Chips, an iconic American brand founded in 1951, to enhance its snack production and enable it to realise its ambitious goals going forward.
The project scope for tna included a complete redesign and optimisation of Mister Bee's manufacturing site in Parkersburg, West Virginia, to achieve a 400 per cent capacity increase.
As the new owners of Mister Bee, the West Virginia Potato Chip Company felt it needed a comprehensive upgrade to the existing frying and packaging machines, which it said were outdated and not suitable for meeting growing market demands. The vision was to create a manufacturing environment that could accommodate expansion while delivering product quality.
Working closely with Mister Bee's operations manager, tna’s engineers said they identified critical process improvements and proposed a tailored solution. The collaboration began with the redesign of the manufacturing space leveraging cutting-edge technologies such as Microsoft’s Hololens. This step ensured that the revamped facility was optimised for efficiency and productivity ahead of integration by tna.
Once the space was mapped out, the installation of the tna robag 3ci, a state-of-the-art vertical form, fill and seal (VFFS) packaging system, followed. Equipped with the rotary double jaw and patented stripper tube closer, tna says the robag 3ci is capable of speeds up to 150 bags per minute (bpm). The inclusion of TNA's patented auto-connect and unload assist technology streamlined operations, facilitating seamless changeovers with minimal manpower, further improving overall equipment effectiveness, according to the company.
Mister Bee reported its chip capacity output skyrocketed, allowing it to meet increasing demand without compromising on product quality.
Mary Anne Ketelsen, president of Mister Bee, expressed her satisfaction with the outcome, stating, “Previous machinery could only run 20-25 bpm, whereas now with my new tna machines, I can run 100-115 bpm. A very big upgrade.”
Furthermore, she said tna’s turnkey, end-to-end, single source approach means the company stands by every element, and this was demonstrated by its swift action in rectifying a small design defect during the integration process. Welders were promptly dispatched at tna's expense to ensure the optimal functioning of the machinery, with Ketelsen and her team saying they were left impressed by tna's dedication to their success.
This partnership marked just the beginning of a long-term relationship between tna solutions and Mister Bee. In subsequent years, Mister Bee has invested in additional tna machinery, including a new fryer. Ketelsen expects this collaboration to continue driving growth and innovation for years to come.
