Fairfields Farm, a UK-based crisps manufacturer, has expanded its production with the installation of an automated snack food packaging system from Ishida. The investment supports the company’s growth in the independent retail sector and is central to its five-year expansion plan.
The company is a customer of Heat and Control, Ishida’s exclusive distributor in the UK and in the ANZ region.
The new line complements an existing system that continues to handle larger pack sizes with lower speed requirements. The Ishida line is designed to operate within the farm’s limited floorspace and delivers higher output, improved quality control, and greater labour efficiency.
The equipment includes an RV series 14-head multihead weigher, Inspira bagmaker, seal tester, checkweigher, and ACP-711 automatic case packer. According to Fairfields Farm, this fully integrated system provides a space-efficient solution to increasing demand.
The multihead weigher and bagmaker combination handles bag sizes from 25g to 150g at speeds of up to 120 packs per minute, representing a 50 per cent increase in output. The weigher operates within 4 per cent of optimum target weight, reducing product giveaway, a key factor for the 40g size, where an individual crisp can weigh up to 1.3g.
The case packer has enabled staff redeployment. Previously, two to three people were required for manual case packing at the end of the line. With the ACP unit installed, these workers have been reassigned to support an additional shift.
Operations director Simon Heard said the new system has made it easier to manage both output and resources. “With manual case packing, we needed two or three people at the end of the line. The Ishida ACP Case Packer freed them up, making it easier to add an extra shift,” he explained.
Flexibility during production was another consideration. The CCW-RV-214 weigher features easily removable hoppers for cleaning during flavour changeovers, while the case packer can switch between formats at the touch of a button.
The line also incorporates automated quality control. The Ishida seal tester and checkweigher work together to reject out-of-specification packs and ensure consistent air-fill during packing. The seal tester sends real-time data back to the bagmaker, allowing automatic adjustments to maintain pack thickness and efficient case packing.
Ease of use was highlighted by Hurd as a further advantage. “The Inspira screen is clear, helping staff quickly identify and resolve any issues. It also supports multiple languages, enabling rapid training of a diverse range of staff,” he said.
Fairfields Farm, run by third-generation farmers, grows its own potatoes and produces crisps on-site. The business has built its presence through independent retailers and continues to invest in sustainability initiatives, including biocrop production, reservoir management and tree planting. It aims to reach net-zero emissions by 2030.
The company said the Ishida installation, commissioned in 2022, was expected to deliver return on investment within two-and-a-half years.
Facts and figures:
- Pack sizes: 25g–150g
- Speed: Up to 120 packs per minute (50% increase)
- Weighing accuracy: Within 4% of target weight
- Labour efficiency: 2–3 staff redeployed to extra shift
- Flexibility: Case packer switches formats at the touch of a button
