In their own words, Just: Gluten Free Bakery in Bellshill are “Bakers on a Mission”, to create and provide a wide range of high-quality gluten free bread products, especially for those who need to avoid certain ingredients. In the creation of their “Just: Great Naan Breads”, the bakery development team recognised the need to supply products with extended shelf life, and specified Modified Atmosphere Packaging (M.A.P.) as a requirement for the project.
PFM UK, Leeds based, specialist supplier of flexible packaging machinery, provided initial support and carried out packaging trials using their demonstration ‘Shamal’ flow wrapper, complete with M.A.P. ‘Gas Flushing’ capabilities and ‘ERS’ long dwell sealing system, to produce hermetically sealed packs.
The Shamal, available in two formats, BA with wrapping material from above and BB with wrapping material from below, is a multi-axis Servo controlled, cantilevered wrapper with a hygienic design and construction which is ideally suited to many food and non-food products.
LVA is an additional feature added by PFM which allows the bag length to be automatically adjusted to suit the product, particularly useful for products with irregular length such as bakery items and fresh produce. Each bag is made to suit the product which not only improves pack appearance it also reduces packaging waste.
Following successful shelf life trials, undertaken by Just: Gluten Free Bakery and their appointed specialist laboratory, PFM were selected to supply the packaging equipment for the project.
Due to tight project timescales and Just: Gluten Free Bakery’s commitment to their Clients, PFM were able to supply the bakery with the demonstration equipment from Leeds, to enable initial production to commence at the bakery, while a new purpose built Shamal flow wrapper was manufactured at the PFM Groups main factory in Schio, Italy.
When the Covid 19 pandemic initially caused global disruption in early 2020, The PFM Group were able to continue construction of the new machine, while operating to strict working practices imposed as a result of the crisis. The machine was subsequently completed within the timescale originally agreed and, following a remote video link PDI, the Shamal was despatched from the factory.
The new machine arrived in the UK, and was en-route to its destination in Scotland, just as the UK and Scottish Governments announced Lockdown. Fortunately, PFM were able to act quickly and divert the delivery to their UK base in Leeds, where the Shamal was safely stored on behalf of the Client, who in turn was able to continue production using the loan Shamal.
Ronnie Stebbings, Managing Director at Just: Gluten Free Bakery added “the whole process from start to finish was relatively seamless irrespective of the covid-19 pandemic. The team at PFM can’t be faulted in the service and knowledge they provide. The installation of this new machine has enhanced our capabilities and offerings to our customers allowing us to expand our product range in an ever growing market. We wouldn’t hesitate in recommending or using PFM again for any future projects”.
As soon as the restrictions permitted, onwards delivery of the new Shamal flow wrapper, together with associated third-party equipment, including gas mixer, analyser/flow monitor and thermal transfer coder, was co-ordinated by the project team at PFM UK. Working under controlled measures on site, the equipment was successfully installed and commissioned by PFM’s skilled engineers, working in collaboration with those of the third-party equipment suppliers and the Client’s own dedicated operatives and staff. Despite the challenges faced by all, production at the Bakery continued seamlessly on the new machine, while the diverse demonstration Shamal was returned to PFM UK, ready for its next project packaging protective face visors.
