A new approach to soft fruit packing: manual and dynamic lines ...

In response to the soft fruit packing problems frequently cited by our customers, Milbor PMC engineers have developed manual and dynamic lines. What are the differences between the two systems and how can they make your business more profitable?

Who are the systems for?

The systems are designed for manual packing of various food products, including soft fruit (such as raspberries, blackberries, and strawberries), vine tomatoes, mushrooms, fish, meat, salads, ready meals and other food products. Specifically for the fruit sector, the packing lines are best suited for companies handling more than 150 tonnes of fruit per season.

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Problems with packaging soft fruit

Operating in the fruit business for over 13 years, we are aware that companies that deal with soft fruit face some specific issues that make their business difficult. There are a few main issues that need to be looked at.

1. Humans required: The product is delicate and must be sorted and packed by hand.
2. There are not enough people to do the work: It’s difficult to find people to do the packing, and it’s even harder to find people who want to pack fruit.
3. Motivation – where have you gone? Many business owners say that their staff are not very efficient, often make mistakes and don’t seem motivated.
4. Each overweight costs a lot: Soft fruit is expensive, so if you use more than the recommended amount, you’ll be making the company less money. When we look at the money that is lost every year, it could be as much as €70,000 for each season.
5. Time is important in the busy season: When a big customer makes an unexpected order, it takes extra hours (and stress) to meet their needs.

Most companies that deal with soft fruit are affected by the above problems. At Milbor PMC, we understand how significant it is to keep things moving. That’s why we’ve created manual and dynamic lines. Both systems can make their daily operations much more effective, and, as a result, let the investors earn more money.

Purpose of weighing systems in a nutshell

Dynamic (semi-automatic) Manual weighing line Products that require minimal sorting Products that require sorting Repacking Products on the vine Weigh control only Low footprint

Manual packing line

It is designed for products that require sorting or products on the vine. The manual line lets you check the weight of punnets that have been packed outside, in the field. The packages go through a 3-decker conveyor and are checked manually by pack house employees who are assigned to the weighing stations. Each station has a precise scale that can be used to check if the punnet is the right weight (no overweight not underweight). Once an employee has corrected the weight, they put the punnet on another deck. There, the package moves on to the next stages of the packing process (e.g. tray sealer, control scale, etc.).

The manual line is flexible. It means that the investors decide about its components and size.

Here is the example of manual packing line layout:

Dynamic weighing line (semi-automatic)

This equipment was created for products that require minimal sorting, either for repacking or weight control only. Due to its compact design, it works well in a pack house with a limited space. The idea behind the dynamic line is the same (production optimalisation), but it consists of different elements. As soon as the fruit-filled packages arrive from the field, where they are weighed manually, they go through a checkweigher to find out the actual weight. Using this information, the 3-lane conveyor with diverter directs the punnet to one of the available paths. Boxes that are the right weight go on path A for more packing. Anything underweight is sent to path B, where an operator manually adds fruit to make it the correct weight. Punnets that are too heavy are sent to Path C. There, an operator will remove any extra fruit to get the weight right. Once they have been adjusted, all packs continue on path A to the next stage of the process. The rest of the line can be changed to suit the customer’s needs.

Here is the example of dynamic packing line layout:

Differences between the manual and dynamic lines

As you can see from the pictures, the systems combine different equipment, and this distinction results in slightly different workflows and outputs. The second option includes a checkweigher combined with a 3-lane conveyor with a separator that automatically determines the path of the crate (hence the name “dynamic”). The manual line requires more effort from the operators. They have to check each packaging individually and add or remove some fruit from an overweight one. In comparison, the dynamic line is slightly less demanding on the operators, as the people at the weighing stations only have to do one type of work: either add product to an underweight punnet or remove fruit from an overweight box.

Similarities between the systems

Both solutions have some important similarities. These include:

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• A measurable upgrade in productivity of around 30% = the job can be done with fewer people and at a lower cost.
• Increased weighing accuracy = less money wasted due to overweight.
• Better operator involvement, also due to improved ergonomics = fewer complaints and better staff retention.
• Flexible design and modular construction = the line can be adapted to the specific needs of the investor.
• High-quality manufacturing = increased durability and reduced risk of failure.
• Reliable, responsive service = in the event of a stoppage or breakdown, you can rely on the immediate assistance of the Milbor service team.

Manual and dynamic lines: more than hardware

In addition to manual and dynamic packaging lines, we have developed Libra software that is compatible with both systems. The software facilitates production management by providing comprehensive reporting on production performance, faster changeovers, live monitoring, reliable data for staff allocation and less paperwork. Our customers find Libra to be an intuitive, easy to use and versatile tool for managing the manual packaging process.

Manual or dynamic line: which to choose?

At this point, deciding between these two systems can be a difficult task. That is why we offer you a free consultation with a Milbor PMC consultant. During the call, we will discuss your business model and prospects to tailor the most suitable solution. The consultation will include an ROI calculation that will show you the costs, benefits, and timeframe of the investment.

Take the first step towards more profitable soft fruit packing, fill out the form below, and arrange a free consultation with our specialist today.

Efficient fruit packing has become increasingly crucial for producers striving to balance product quality, labour constraints, and profitability. Addressing these needs, Milbor PMC offers two tailored solutions: the manual weighing line and the dynamic weighing line. Both systems have their own advantages, says Piotr Milewski, CEO of Milbor PMC.

According to Milewski, the manual weighing line is ideal for products requiring careful sorting, such as strawberries or raspberries. "This system relies on human operators, who manually verify the weight of each punnet using precise scales placed at weighing stations. When a package is overweight or underweight, the operator adjusts its weight manually before it moves to the next processing stage. The primary advantage of this system lies in its efficiency combined with accuracy. Manual weighing line minimises product waste and supports ergonomic working conditions, thereby enhancing employee engagement and reducing costly overfilling mistakes. The line can be customised and adapted to any packing facility."

© Milbor sp. z o.o

For operations where products require minimal sorting, weight control only, or repacking, the dynamic weighing line offers a semi-automatic alternative, Milewski explains. "This system uses a checkweigher and a 3-lane conveyor with a diverter that automatically directs packages based on their weight. Only underweight or overweight packages are routed for manual adjustment. Once the weight is correct, the punnets go to the next stage. Thanks to its compact design, the dynamic line is an interesting choice for pack houses with limited space. It significantly reduces operator workload, as employees focus solely on adding or removing fruit, rather than conducting full weight checks."

© Milbor sp. z o.o

Milewski states that despite their differences, both systems deliver notable improvements in productivity, about 30%: "The system also reduces operational expenses by decreasing labour requirements and minimising losses from overweight products. Furthermore, they share a modular design, allowing for future adjustments and scalability, as well as feature increased durability thanks to high-quality manufacturing."

"With these solutions, fruit producers can measurably reduce overweight losses and increase work efficiency while keeping gentle handling of delicate products. Selecting between the manual and dynamic weighing line depends on the product, sorting requirements, and operational goals. To explore more about both solutions, find out if they fit your business model and calculate ROI, please contact the Milbor PMC advisor," Milewski concludes.

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