Supermarket chain Delhaize has collaborated with DS Smith to reconfigure a bag-in-box wine packaging line at its plant in Zellik, Belgium.
The equipment and materials upgrade lifted the line’s operating speeds from 1,500 to 1,900 packs per hour.
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The net throughput gain of 400 packs per hour was realised by modifying the container design and processing machinery in tandem.
Departing from the conventional practice of purchasing cartons and equipment through separate supply chains, DS Smith manufactured a forming machine matched directly to Delhaize’s bag-in-box packaging format and line requirements.
DS Smith Central EMEA sales marketing & innovation director Kim Radelet said: “This project demonstrates that the greatest opportunities for improvement often lie beyond the packaging itself. By looking at the entire system, from packaging design and materials to machinery performance, storage and operational efficiency, we helped Delhaize unlock 27% more capacity from its existing operation.”
Synchronising the mechanical tolerances directly with the corrugated packaging stabilised the run, raised finished pack quality, and eliminated virtually all line stoppages, according to the packaging firm.
Beyond line reliability, the mechanical adjustments reduced the number of operators needed to run the station.
Logistics operations also saw space utilisation gains, with warehouse density expanding from 5,000 to 6,000 packs per storage location.
Delhaize is a subsidiary of food retailer Ahold Delhaize, which operates physical supermarkets and online retail services across trading banners including Delhaize, Albert Heijn, Albert, Maxi, Food Lion, Gall & Galll, Mega Image, Alpha-Beta, Hannaford, Stop & Shop, and The GIANT Company.
Delhaize Belgium production & technical manager Hervé Louis said: “What sets DS Smith apart is its ability to optimise both packaging and machinery as a single solution.
“The interaction between those two elements is critical, and by aligning them from the start, we have been able to increase throughput, reduce downtime and make better use of our existing capacity.”
