To successfully modernize and scale up production lines in response to the recent increase in consumer demand, several key factors need to be considered. We’ll delve into these factors throughout this article, so read on.

Potato processors must completely comprehend inefficiencies in their supply chain and pinpoint obstacles before expanding their production capacity. To accommodate the increased throughput, producers must update their systems before strategically growing production. More than merely increasing throughput and speed is involved in scaling.

It’s critical to have real-time control over a variety of fundamental components, such as sorting settings and process modifications. Experts advise investing up front in a solid supply chain strategy to guard against disruptions brought on by seasonality, shifting customer preferences, and international crises. Producers should think about whether they have adequate staff and machinery to handle higher production volumes, as well as if their products have a long enough shelf life to support the production schedule.

Automated Key Processes in the Manufacturing Operation

Automating critical manufacturing processes is one strategy to increase productivity and expand the company. Since the industry’s major players have been utilizing automation for years, the technology has become more widely accessible and reasonably priced. The time has come for smaller businesses to invest in automated systems, even though they may not have had the resources to do so in the past due to the demand for more user-friendly and reasonably priced equipment.

Since many tuber processing technologies have not changed significantly over the past few decades, updating existing machinery may be a more cost-effective option to automate production. Investing a small portion of the cost of new equipment lowers labor costs. Even though the updated machinery may not be as future-proof as the more recent models, it nevertheless allows businesses without the capital to purchase new equipment to compete with more advanced automated manufacturing lines.

PepsiCo has Chosen Mecalux Intralogistics Solutions to Equip Its Veurne Factory

Mecalux, an intralogistics business, will outfit PepsiCo’s facility in Veurne, Belgium. This factory is one of Europe’s largest potato chip manufacturers.

PepsiCo’s Belgian business opted to restructure its logistics operations by developing a fully automated storage and retrieval system (AS/RS) to house the daily production of 2m bags of chips and snacks from the Lay’s, Doritos, Bugles, and Cheetos brands.

To accomplish this purpose, PepsiCo will install Mecalux’s Automated Pallet Shuttle technology. The AS/RS is one of the most efficient high-density storage technologies available, resulting in extraordinarily high product inflows and outflows. To speed internal product movements, the Automated Pallet Shuttle system will be linked to PepsiCo’s manufacturing plant via a 100-meter-long conveyor line. The AS/RS will have four aisles, with two blocks of racking on each side. Twelve transfer vehicles (one for each storage level) will transport commodities to their respective storage channels. Once there, a mechanized shuttle car will deliver pallets to their designated positions.

PepsiCo will also implement Mecalux’s Easy WMS warehouse management system for real-time stock control. This software will be integrated with the company’s ERP system to ensure that operations run smoothly. It will coordinate the flow of products, managing their journey from production to the AS/RS as well as their seamless preparation for distribution to clients.

PepsiCo acquired the factory in Veurne 25 years ago. Since then, the facility has become one of the largest crisps and snacks production plants in Europe. It spans more than 40,000 square meters, the size of eight football pitches, and stands out for its cutting-edge and sustainable technology. The new AS/RS from Mecalux will complement the Veurne plant.

You can read the rest of this article in your complimentary e-copy of Issue 2 of Potato Business Dossier 2024, which you can access by clicking here.