In the highly competitive salmon and trout processing industry, success relies on a delicate balance between output and precision. Lerøy Seafood France, a subsidiary of one of the world’s leading companies in the industry, has turned its plant into a model of responsiveness. To support its fast-paced production in Saint-Laurent-Blangy, the company chose to secure and modernize its fleet of packaging equipment with several SEALPAC machines.
Demanding and structured environment
Lerøy Seafood France serves three main segments: Retail (large and medium-sized supermarkets with private-label products requiring consistent quality and attractive presentation), Foodservice (out-of-home catering with a variety of ready-to-use formats for wholesalers and restaurants), and Industrial (business-to-business markets with standardized, often frozen products). Every stage of production is subject to a high level of accuracy: receipt of gutted salmon or fillets ready for processing, storage at 0 to 2°C, and integration into an ERP system to ensure full traceability. To support its growth and meet market demands, the company chose to leverage SEALPAC’s expertise to modernize and enhance the reliability of its packaging operations.
Streamlined and fully secure production chain
From the moment raw materials are received, the company demonstrates a high level of precision. The salmon, delivered either whole and gutted or as fillets ready for processing, are received at refrigerated unloading docks and stored between 0 to 2°C. Each batch is entered into an ERP-driven traceability system, ensuring a continuous link between raw material and finished product, an essential requirement to meet the demands of large-scale retail and quality certifications. The process continues with automated filleting, mechanical deboning, trimming, and fixed-weight slicing. Portioning machines enable fixed-weight cutting through the scanning of each fillet and density calculation. This level of control helps secure product quality while maintaining a high industrial throughput. Production flows are therefore perfectly synchronized, reducing waste and variation. In a full-value optimization approach, by-products are further processed into value-added preparations (pan-fried items, ready-to-eat products), enhancing the overall profitability of the production system.
Packaging then becomes a key stage, where the collaboration with SEALPAC fully comes into play. The machine park, comprising four SEALPAC A5 traysealers, one brand-new A6max traysealer, and one RE25 thermoformer, provides the flexibility needed to meet diverse market requirements. This setup also enables optimized distribution of production flows across lines, depending on formats, output, and order priorities. Finally, packaging relies on the balance between machine, tray, and film. SEALPAC solutions secure and optimize this trio by automatically adjusting film tension, speed, and indexing according to formats, ensuring consistency and efficiency.
Solutions designed for productivity and flexibility
SEALPAC machines are not just pieces of equipment, they embody a global approach to packaging. Each traysealer or thermoformer integrates innovative solutions that enable:
- Increased output without compromising quality: production lines can reach and exceed industrial standards while maintaining consistent pack quality
- Improved ergonomics and operator experience: intuitive and readable interfaces allow teams to quickly master the machines and perform tool changes themselves, reducing reliance on technicians
- Simplified format changes and product versatility: thanks to intelligent indexing systems on the traysealers, such as SmartCord, these machines automatically detect the tray length and adjust spacing, making format switches easier and reducing downtime
- Enhanced reliability and preventive maintenance: on the new A6max traysealer, precise tracking of tool cycle counts enables predictive maintenance and minimizes unexpected interruptions
- Optimal film handling and sealing consistency: SEALPAC’s servo-driven machines guarantee precise film control, contributing to stable packaging performance and reduced material waste
These solutions are not purely technical, they transform the way operators interact with their equipment, making packaging simpler, safer, and more efficient. As Aziz Sahia, Director for Industrial at Lerøy Seafood France states: “We are fully satisfied with the latest A6max traysealer, which has significantly increased our productivity by 25% to 33%, depending on the formats used.” Sarah Reske, Production Supervisor at Lerøy Seafood France, adds: “The interface of the A6max is easier to read and understand. You can simply increase the number of cycles, which boosts the overall output. Better productivity, easier operation. It’s the best!”
Compliance and food safety
Production at Lerøy Seafood France operates within a highly demanding regulatory framework. To work with large-scale retail, the company must comply with strict standards such as IFS Food, BRC, or ISO 22000 certifications, which ensure food safety, traceability, and consistent product quality. The hygienic design, simplified cleaning, and smart interfaces of the SEALPAC machines ensure that packaging is always carried out in accordance with these standards. Operators can easily follow cleaning protocols, adjust settings, and document production batches, which reduces the risk of errors and facilitates inspections. Lerøy Seafood France is able to combine productivity, flexibility, and food safety while remaining aligned with the most stringent regulatory requirements, which is a key factor in maintaining customer trust and brand reputation.
