The Authentic Food Company – Investing For A Tasty Future!

By: CKF Systems
 
April 18, 2013 - PRLog -- Established in 1985, The Authentic Food Company (TAFC) has become one of the leading suppliers of international foods in the UK. Its customers include several leading supermarket brands and national pub chains and the depth of its achievements extend to award winning recipes, recognition from the Vegetarian Society and three consecutive Gold awards from the British Frozen Food Federation (BFFF).

The Manchester-based family owned business is proud of the strong relationships it enjoys with all its employees and its ongoing commitment to promote employee wellbeing with the recent achievement of the Investors In People Gold Standard award TAFC sits on the Parliamentary Forum and several committees for the British Frozen Foods Federation, has recently renewed its ISO 14001 for the third consecutive year for green business management systems and continues to operate all aspects of its business in an ethical, environmental and rewarding way.  

In 2010, the company celebrated 25 years in business with an ambitious multi-million pound five year growth plan based upon a three phase investment programme. In partnership with automation and robotics specialists CKF Systems Ltd, phase one is now fully operational and the impact has been immediate.

The relationship with CKF began in 2000 when TAFC moved to premises in Sharston, Manchester and commissioned CKF to design and install a manual packing line to accommodate frozen products.

“In the 12 years we have worked with CKF we have formed an excellent working partnership,” explains Mike Rimmer, Group Engineering Manager, of TAFC. “They are sympathetic to our business and understand how we operate. We trust them in their thought processes, decision making and delivery. It was an easy decision to invite CKF to work with us on this project.”

To ensure no disruption to production, the first phase was scheduled to take place during the Christmas shut down, a window of just eight days.

TAFC removed a series of internal walls to increase the size of the existing packing hall and accommodate the third packing line. In planning for later phases, it was essential that all three packing lines would terminate in a central location adjacent to the area for palletising operation. The two existing lines were reconfigured by CKF to achieve the overall layout objectives and create space for the additional line. This required the introduction of two new spiral conveyors at the outfeed of the freezer to de-elevate the products within the minimum floor area. Each line incorporated line inspections, manual packing stations, case closing, coding stations and stackdown facilities.

The third line utilised another new de-elevating spiral conveyor and incorporated the same features as the existing lines plus a bypass arrangement to a sleeving machine.

The manual packing stations on all three lines were designed to accommodate initial hand packing needs and to allow ease of replacement with planned future auto case /carton loading machines i.e. identical footprints. A new high level gantry was designed and installed at the outfeeds of the two spiral freezers to allow ease of access for production, hygiene and maintenance purposes.

CKF assumed full responsibility from initial layout design through manufacture, installation and commissioning, including associated electrical control systems. The programme was completed on time.

“The complexities of the project meant that the shut down period offered almost no margin for error,” continues Mike Rimmer. “Thankfully, with CKF’s support the project was completed to plan and when our workforce returned for the New Year we were operational. The new system has had a positive impact across almost every aspect of our business.”

By expanding from two to three lines, TAFC has increased its capacity and added flexibility. A 20% increase in production has enabled the company to meet the growing demand for its meals, explore new opportunities and develop new ventures with increased vigour. One such example is the recent collaboration with Yu and You, a leading Cantonese Restaurant which has enabled TAFC to capitalise on the increasing appetite for new flavours in this growing market.

Yu and You won Gordon Ramsay’s ‘Best Chinese Restaurant’ in the UK 2010.

“Our work force has embraced the changes,” enthuses Mike. “The new system has improved efficiency and reduced wastage. Enhanced ergonomics have had a direct and positive impact upon our LEAN programme; designed to improve quality of all process outputs and at the heart of everything we do!”

For a company that takes such pride in the wellbeing of its employees, the improvements in the working environment have been warmly welcomed. Equally as rewarding is a reduction in the company’s carbon footprint with energy consumption down by around 10%.

“With such huge growth plans, it was imperative that the first phase was successfully implemented,” concludes Mr Rimmer. “It is now fully operational and in line with our expectations. With the support of CKF we shall shortly be embarking on the next phase.”
End
Source:CKF Systems
Email:***@polygon.uk.com Email Verified
Tags:Ckf, Authentic Foods, Gordon Ramsay, Kevin Staines, Mike Rimmer
Industry:Manufacturing
Location:England
Subject:Projects
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