With a new flexible film solution for selected products, Süddeutsche Truthahn AG in Germany has made a significant investment in the area of thermoformer packaging. Since January 2024, a SEALPAC F-series thermoformer has been added to the poultry processor’s machine park, which achieves an output that is around 3.5 times higher compared to its previous equipment. Increased performance, as well as economical use of materials, optimal hygiene, and innovative features, such as quick and easy tooling exchange systems, make the F-series a real game changer in the thermoforming segment. This has led to great enthusiasm at Süddeutsche Truthahn AG.
Southern German market leader for turkey meat
White meat is trending in Germany and throughout Europe. The proportion of poultry meat is generally growing faster than the market for other animal protein as a whole. Süddeutsche Truthahn AG also benefits from this. With 750 employees at its Ampfing location, the subsidiary of the listed Bell Food Group is the southern German market leader for turkey meat. Around 84 percent of its products are destined for the German market, whereas about 12 percent goes to Austria and Switzerland. Since the COVID pandemic, the demand in the catering and wholesale segment for turkey as a classic food service product has declined somewhat, but the demand among consumers has continued to gain momentum: approximately 70 percent of the poultry specialist’s items are intended for retail.
At the Ampfing site, around 100,000 tons of poultry are processed into 40 different turkey meat products annually. Orders are often received at short notice and are delivered five days a week. Many different factors influence the weekly production quantities. When the weather peaks during the barbecue season, the demand skyrockets. In order to be able to respond optimally to customer requests at all times, Süddeutsche Truthahn AG requires high-performance, particularly flexible, and reliable packaging technology. The equipment must also be suitable for addressing current and future packaging trends. In the poultry segment, for example, food retailers are increasingly demanding flexible film packaging for turkey legs and other poultry products, as it allows for safe and attractive packaging under vacuum or modified atmosphere. Retailers benefit from these packaging solutions, because the products can be easily presented in a small space on the refrigerated shelves. The economical, resource-saving use of materials is also driving the current demand for flexible film packaging.
Future-proof thermoforming technology
In order to be able to cope with the trends in the poultry segment comprehensively and reliably, those responsible at Süddeutsche Truthahn AG intensively searched for the right thermoforming technology. A new, modern solution not only had to replace the outdated existing thermoformer, but also had to mark a significant technological step into the future. The poultry processor’s specifications were demanding: the new thermoformer had to combine high output with maximum flexibility and short set-up times, which can be a challenge from a technical perspective. Süddeutsche Truthahn AG relied on its long-time partner Sealpac GmbH. This German packaging specialist, based in Oldenburg, with whom the poultry processor has been cooperating for over two decades, already supplied more than 20 packaging machines at the company’s plants in Germany and Austria.
SEALPAC’s portfolio includes thermoformers in all performance classes, from entry-level models to high-end solutions like in this particular project. During a visit to the factory in Oldenburg, the decision makers from Ampfing familiarized themselves with SEALPAC’s F-series thermoformer. This newly designed, high-performance packaging machine has several unique features that revolutionize the production of thermoformer packaging globally. The representatives of the poultry meat company were particularly impressed by the low downtime and high flexibility of the machine. The ultra-modern hygiene concept of the new F-series, such as its easy-to-clean design, was particularly well received by the company’s Quality Assurance officer. And so the decision was soon made in favour of SEALPAC’s latest generation of thermoformers.
Intensive coordination, smooth installation
In the demanding project phase, SEALPAC’s engineers adapted the design of the new thermoformer to both the spatial situation and the existing processes in Ampfing, but also to the dimensions of the products that were going to be packaged in flexible film. The most important goals included not only a significantly increased output, but also an expansion of the range of flexible film solutions on site. The new machine in mirrored design was configured to run vacuum packaging, not only for turkey breasts but also for whole turkey legs. During the execution of the project, the engineers in Oldenburg collaborated closely with the technicians of Süddeutsche Truthahn AG. This allowed SEALPAC to incorporate many of the technical details that were on the poultry processor’s wish list into the design of the new packaging line.
In January 2024, finally the time had come. In order not to disrupt the operations at Süddeutsche Truthahn AG, SEALPAC’s technicians installed the new thermoformer over a weekend. The first test runs were conducted on the following Monday and regular production at the poultry company started as early as Tuesday. Its in-house technicians were already familiar with the characteristics of the thermoformer through SEALPAC’s training courses. In order to provide assistance swiftly, if necessary, the engineers in Oldenburg can access the customer’s machine remotely at any time to conduct a short-term analysis, or just provide a quick tip every now and then.
Quick tooling exchange systems support high performance
Right from the start, the new F-series thermoformer impressively demonstrated its unique performance. With regard to the poultry processor’s smaller products, the thermoformer achieves an output of 90 packs per minute. With the larger formats for products of around 1.5 to 2 kg, the packaging machine achieves around 3.5 times the performance compared to previous solutions. When selecting a programme on the brand-new F-series thermoformer, the machine automatically adjusts itself to the stored basic settings for that respective packaging format.
Süddeutsche Truthahn AG was already familiar with SEALPAC’s innovative tooling exchange systems from its numerous existing machines. This has now been extended to the latest generation F-series thermoformers. It simplifies switching between different applications and avoids unnecessary machine downtimes. The replacement of the sealing top tool takes place without any hand tools and with minimum effort. It is unlocked pneumatically at the push of a button and can then be easily pulled into the tooling exchange trolley. This means that an exchange is not only much quicker, but also safer for the employees in the poultry plant, who no longer have to lift or carry heavy components. In the meantime, the bottom forming tool can be swung out with an innovative turntable. The trained employees in Ampfing now conduct their format changes in a significantly shorter time. The poultry processor was able to reduce its machine downtime overall by at least 50 to 60 percent, a noticeable pay off.
Operating data in real time, optimally planned maintenance
With the new thermoformer, Süddeutsche Truthahn AG was also able to take a significant step into the future in terms of digitalization. Being part of a large group, the company depends on accurate information as the basis for its annual planning. Reliable production and operating data are key here. The F-series thermoformer is already tailored to this requirement by offering detailed and systematic data in real time. It not only provides information about the current operating status, the cycle count, stops conducted, and possible errors, but also signals upcoming maintenance so that the poultry processor can plan this optimally.
Compliance with PPWR: smooth processing of mono-materials
Another aspect played a crucial role in the decision to purchase SEALPAC’s F-series thermoformer: compliance with the EU’s new PPWR (Packaging and Packaging Waste Regulation). In the future, when designing the right food packaging, there is no way to neglect recyclability. Here, all food manufacturers are working together with their packaging partners on feasible solutions. This always affects the entire pack, from the tray or bottom and top film to the label and absorption pad. It can be a real challenge, because in many cases these components are not yet fully recyclable. In the future, food manufacturers will have an even greater responsibility and will be dependent on close cooperation with their suppliers of consumables.
The new F-series thermoformer is fully prepared for this challenge. Just like the latest generations of SEALPAC traysealers, it is designed to process modern, recyclable, mono-materials without any problems, regardless of whether the European market tends towards PP (polyolefin material group) or PET (polyester material group) in the future. With the new F-series, Süddeutsche Truthahn AG now finds itself well positioned in the thermoforming segment to fully meet the requirements of the PPWR, and thus the wishes of the large retailers.
The F-series: a game changer in the thermoforming segment
In the meantime, the F-series thermoformer has been in operation at the poultry processor for several months. Despite this relatively short period of time, those responsible at Süddeutsche Truthahn AG are convinced that they have taken the right path by choosing a top-quality solution. Additional steps are now being planned. In order to fully exploit the performance of the line, down-stream components, such as weighing systems, will be upgraded. Here too, the food manufacturer benefits from the flexibility of the F-series. It is not SEALPAC’s philosophy to dictate customers which up- or down-stream equipment to use. That is entirely up to them. The individual customer requests are always clearly determined and technically checked. With its packaging machines, the company gives its customers freedom of choice and sees it as its task to make excellent synchronizations possible across the entire line. This has resulted in a high level of satisfaction at Süddeutsche Truthahn AG, where the new F-series thermoformer already proved to be a real game changer.