Installing A High-Speed Salad Layering Line With Sealpac UK and Partners

The Challenge

A customer had recently taken on the production of layered salad and pasta products from another supplier. These were complex and tricky products, and the customer needed two high-speed lines capable of producing between 60 and 70 packs per minute. To meet these demands, they wanted a brand-new line built from the ground up — one that could deliver both speed and reliability.

The Goal

The project’s objectives were clear:

• Design and install two high-speed salad layering lines (60–70 packs/min).

• Ensure the system could handle complex layered products.

• Designed to handle 30 different recipes and also be flexible for future recipes.

• Incorporate hygienic design for easier cleaning and maintenance.

• Reduce labour requirements through automation.

• Deliver and install the solution with minimal disruption to ongoing production.

The Solution from Sealpac UK & Partners

Sealpac UK & Partners approached the project as a collaborative build, working hand in hand with suppliers to design a solution around every one of the customer’s requirements. The final solution brought together eight Cabinplant multihead weighers, twenty Qupaq denesters and automation units, and six Antares Vision Group inspection systems, all seamlessly integrated into two lines that deliver high-speed, precise, and quality-controlled production.

But bringing this ambitious solution to life was not without challenges. The factory had to remain operational throughout the installation, so our team worked in and around live production. Space was tight, access was restricted, and the floor gradients had to be factored into the design. On top of that, existing service supplies were outdated and had to be completely redone. To keep everything on schedule, we coordinated third-party contractors to carry out service works in parallel with the installation.

The project demanded careful management: safety was the top priority, disruption to ongoing production had to be kept to a minimum, and the installation window was narrow — just one week per line to complete the mechanical and electrical fit-out and power-up. By working closely with the customer and suppliers, the team successfully navigated these hurdles.

The completed lines not only delivered the required 60–70 packs per minute but also introduced several long-term advantages: a more hygienic design with elevators that could be lifted and lowered for easy cleaning; and the ability to handle tricky or sticky products with ease. Automated tray denesting reduced labour requirements, and the line was designed to be adaptable for new products in the future.

Key Highlights:

• Fully integrated solution with weighers, denesters, automation, and inspection systems.

• Delivered at speed despite live production and factory constraints.

• Hygienic design with elevators for easy cleaning and integrated wash walls to store and clean all weigher components.

• Flexible to handle both current and future products.

• Automated tray denesting reduced labour needs.

• Collaborative approach with other suppliers and the customer.

Conclusion

By combining teamwork, smart engineering, and meticulous project management, Sealpac UK & Partners provided the customer with tailored high-speed lines designed for today’s complex products and tomorrow’s new challenges. The result is a hygienic, flexible, and labour-efficient solution that delivers precision at speed — proving once again that when the demands are tough, the right team will always find a way.

Challenges are part of the job, but its our approach what turns them into solutions - coordinating multiple teams, adapting factory services, and installing without stopping production.