THE NO.1 CZECH MEAT COMPANY ADOPTS CRYOVAC® PACKAGING AUTOMATION TO BOOST QUALITY AND SALES
Located in the Vysočina region, Kostelecké uzeniny is the largest meat and meat products manufacturing company in the Czech Republic with a market share of approximately 7%. The company’s product range includes fresh pork, beef and poultry. The flagship product is fermented salami covered with fine natural mould. The company was the first one to introduce these original long shelf-life salamis in the Czech market and is the only one able to industrially produce and supply it in high volumes. With its high quality, this processed meat ranks among premium meat products.
The company’s annual sales amount to approximately EUR 150 million, with 10% for export to Germany, Poland, Slovakia and Austria. Kostelecké uzeniny is an example of successfully combining the traditions of the Czech food industry and modern company development. All the company’s operations rank among the most progressive ones in Europe thanks to state-of-the-art facilities and technologies. The company has become a leading meat processor and meat product producer in the Czech Republic.
The company is a significant supplier to multinational chains, as well as to retail associations and traditional markets. The Kostelecké uzeniny brand is mostly designed for traditional Czech gastronomy products, building on the tradition and experience of master butchers since 1917.
(firmenpresse) - ENHANCED PACK PERFORMANCE
Under insistent pressure from retailers to improve packaging performance, the decision was taken in early 2008 to upgrade from standard shrink bags to high performance shrinkable films and automation. Long-time packaging partner Sealed Air Cryovac provided the perfect solution with Cryovac® RS2000 film running with the innovative Cryovac® Ulma Flow-Vac® system. Kostelecké installed the FV45 that is based on horizontal form-fill-seal technology operating at very high speeds and loading into Cryovac® vacuum equipment.
The new packaging system immediately provided a number of advantages. The low impact investment in automation adding to an already existing flat belt vacuum chamber allowed a user-friendly and flexible change with substantial benefits, such as improved meat quality, longer shelf life thanks to shrinking and vacuum properties, or better pack appearance due to the Flow-Vac® automatic adaptation of bag length to product length. Consequently, productivity was enhanced as the need for repacking – due to rejects or meat contamination on seals – dropped significantly. Last but not least, the level of hygiene was enhanced.
Automation brings increased productivity, higher packaging speed, flexibility, as well as decreased labour costs. In addition to economic benefits, an increased level of hygiene and safety is observed as a significant benefit because operator contact with the meat is avoided. Indeed, after processing and deboning the meat goes directly to the packing room without further handling by operators and therefore limiting possible contamination.
LONG TIME SUPPORT AND PARTNERSHIP
The process of changing to a highly efficient automatic packaging system proved easy and seamless thanks to the long-term support and partnership offered by Sealed Air. Initial presentations and an introduction to the system were quickly followed by training, and marketing and technical support leading to the new line start-up in 2008. More specifically, operators adapted very quickly to the new system.
“We are very satisfied with Cryovac and Flow-Vac®. All machines and materials have been performing very well – never requiring any extraordinary service. All operators adopted the system well and quickly with a high level of satisfaction”, said the Managing Director.
GREAT SUCCESS WITH RETAILERS AND CONSUMERS
The newly packed products have been distributed via Tesco, the Makro / Metro chain, smaller retailers, as well as hotels and restaurants. Retailers now benefit from high quality selected meat processed under top hygienic conditions and high safety standards. Longer shelf life is another advantage, reaching around 10 days. As the meat is vacuum packed, its quality is also enhanced.
Smaller retailers enjoy an additional benefit as they can store the meat in the cool cabinet without juice leaking or releasing any contamination, and portion it only when needed. As a result, savings are also achieved in handling, transportation and storage.
All the benefits afforded by the Flow-Vac® system in terms of longer shelf life, increased hygiene and improved meat quality are setting the standards of meat acceptance from retailers. Today Kostelecké uzeniny is considered the meat processing and packing “reference” in the Czech Republic.
The new packaging was also very positively received by consumers, resulting in a significant increase in sales. According to surveys carried out by retailers, final consumers truly appreciate the higher meat quality.
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MORE ABOUT KOSTELECKÉ UZENINY
Located in Kostelec near Jihlava, Vysočina Region, the joint-stock company Kostelecké uzeniny has a long history and tradition in production of meat products. The processed meat and canning factory was founded in 1917 and its products gradually became well-known and popular throughout former Czechoslovakia.
The joint-stock company Kostelecké uzeniny was established by privatisation in 1992. The factory underwent thorough modernisation. New large-capacity plants gradually replaced former obsolete facilities and the right conditions were created for the integration and specialisation in meat production and processing. Today this highly developed enterprise is ready and able to compete with similar companies throughout Europe thanks to its traditions, human resources and technical potential.
With almost 1,350 employees, Kostelecké uzeniny operates four plants (the following plants are located in Kostelec: Plant CZ 966 – Poultry Processing Plant, Plant CZ 333MV – Meat Production, Plant CZ333J – Slaughtering Plant, and one plant is located in Hodonin, South Moravia, for case-ready meat packaging). Its annual production volume of 65,000 tons in 2008 and turnover of approximately EUR 150 million have been growing steadily. The growth forecast for this year is around 5 to 6%.
MORE ABOUT CRYOVAC® ULMA FLOW-VAC® LOADER
Unique in the industry, this cost-effective loader combines horizontal form-fill-seal technology with vacuum shrink packaging. It is designed to be used with the new Cryovac® RS barrier shrink materials range featuring high sealability through pleats, as well as superior optics and shrink.
The Cryovac® Ulma Flow-Vac® system self adjusts the packaging length to the product length. Thanks to the low reel machine configuration, the product never comes into contact with the sealing areas, which prevents contamination and ensures a high quality seal. This machine also generates significant cost savings: labour savings with easy product flow and reduced manning at loading stage, plus material savings through optimal consumption.
MORE ABOUT SEALED AIR
Cryovac® is a registered trademark of Cryovac Inc., a subsidiary of Sealed Air Corporation.
Flow-Vac® is a registered trademark of Ulma CyE S. Coop.
Cryovac Packaging and Cryovac Food Solutions are business units of Sealed Air and global leaders in innovative flexible and rigid packaging materials, systems and services for a wide range of food applications.
With more than 3,000 employees throughout the region, Sealed Air in Europe, the Middle-East and Africa (EMEA) operates manufacturing facilities in France (Arc-en-Barrois and Epernon), Germany (Norderstedt), the UK (St. Neots and Poole), Italy (Passirana di Rho), Spain (Buñol), Russia (Volgograd), Poland (Ozarow), Hungary (Újhartyán), South Africa (Spartan) and Botswana (Lobatse). Also located at the Italian site is the Sealed Air EMEA Packaging Technical Center. The EMEA Customer Systems Center is located in Root, Switzerland. Packforum®, Sealed Air Cryovac EMEA’s permanent customer care center, is located at Roissy Charles de Gaulle near Paris, France.
Sealed Air is dedicated to permanently improving its environmental performance and strives for safety and environmental excellence, while also ensuring that plastic food packaging is more efficient than ever. The company is actively engaged in source reduction and total material utilisation through recycling or reuse of industrial scrap, otherwise energy recovery through appropriate incineration.
For more information on this success story,
please contact Angelika Steiner:
Tel: +41 41 349 4593 or Angelika.Steiner(at)sealedair.com
For more information on this success story,
please contact Angelika Steiner:
Tel: +41 41 349 4593 or Angelika.Steiner(at)sealedair.com
Datum: 11.06.2010 - 05:43 Uhr
Sprache: Deutsch
News-ID 1016042
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contact information:
Contact person: Angelika Steiner
Town:
Root
Phone: +41 41 349 4593
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Various
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