Czech Meat Company Adopts Cryovac Packaging Automation To Boost Quality And Sales

Kostelecké uzeniny is the largest meat and meat products manufacturing company in the Czech Republic with a market share of approximately 7%. The company's product range includes fresh pork, beef and poultry. The flagship product is fermented salami covered with fine natural mould. The company was the first one to introduce these original long shelf-life salamis in the Czech market and is the only one able to industrially produce and supply it in high volumes. With its high quality, this processed meat ranks among premium meat products.

The company's annual sales amount to approximately EUR 150 million, with 10% for export to Germany, Poland, Slovakia and Austria. Kostelecké uzeniny is an example of successfully combining the traditions of the Czech food industry and modern company development. All the company's operations rank among the most progressive ones in Europe thanks to state-of-the-art facilities and technologies. The company has become a leading meat processor and meat product producer in the Czech Republic.

The company is a significant supplier to multinational chains, as well as to retail associations and traditional markets. The Kostelecké uzeniny brand is mostly designed for traditional Czech gastronomy products, building on the tradition and experience of master butchers since 1917.

Enhanced Pack Performance
Under insistent pressure from retailers to improve packaging performance, the decision was taken in early 2008 to upgrade from standard shrink bags to high performance shrinkable films and automation. Long-time packaging partner Sealed Air Cryovac provided the perfect solution with Cryovac® RS2000 film running with the innovative Cryovac Ulma Flow-Vac system. Kostelecké installed the FV45 that is based on horizontal form-fill-seal technology operating at very high speeds and loading into Cryovac vacuum equipment.

The new packaging system immediately provided a number of advantages. The low impact investment in automation adding to an already existing flat belt vacuum chamber allowed a user-friendly and flexible change with substantial benefits, such as improved meat quality, longer shelf life thanks to shrinking and vacuum properties, or better pack appearance due to the Flow-Vac automatic adaptation of bag length to product length. Consequently, productivity was enhanced as the need for repacking – due to rejects or meat contamination on seals – dropped significantly. Last but not least, the level of hygiene was enhanced.

Automation brings increased productivity, higher packaging speed, flexibility, as well as decreased labour costs. In addition to economic benefits, an increased level of hygiene and safety is observed as a significant benefit because operator contact with the meat is avoided. Indeed, after processing and deboning the meat goes directly to the packing room without further handling by operators and therefore limiting possible contamination.

Long Time Support And Partnership
The process of changing to a highly efficient automatic packaging system proved easy and seamless thanks to the long-term support and partnership offered by Sealed Air. Initial presentations and an introduction to the system were quickly followed by training, and marketing and technical support leading to the new line start-up in 2008. More specifically, operators adapted very quickly to the new system.

"We are very satisfied with Cryovac and Flow-Vac. All machines and materials have been performing very well – never requiring any extraordinary service. All operators adopted the system well and quickly with a high level of satisfaction", said the Managing Director.

Great Success With Retailers And Consumers
The newly packed products have been distributed via Tesco, the Makro / Metro chain, smaller retailers, as well as hotels and restaurants. Retailers now benefit from high quality selected meat processed under top hygienic conditions and high safety standards. Longer shelf life is another advantage, reaching around 10 days. As the meat is vacuum packed, its quality is also enhanced.

Smaller retailers enjoy an additional benefit as they can store the meat in the cool cabinet without juice leaking or releasing any contamination, and portion it only when needed. As a result, savings are also achieved in handling, transportation and storage.

All the benefits afforded by the Flow-Vac system in terms of longer shelf life, increased hygiene and improved meat quality are setting the standards of meat acceptance from retailers. Today Kostelecké uzeniny is considered the meat processing and packing "reference" in the Czech Republic.

The new packaging was also very positively received by consumers, resulting in a significant increase in sales. According to surveys carried out by retailers, final consumers truly appreciate the higher meat quality.

SOURCE: Kostelecké uzeniny