Automated Hygienic Packaging Line for Leading Global Snack Manufacturer

Client

Major International FMCG Company (confidential – one of largest snack and ready-to-eat food producers)

Industry

Food & Beverage

The Challenge

The client’s manual flatbread (chapati/roti) and snack packaging line was struggling with inconsistent portioning, high labour dependency, frequent contamination risks, and inability to meet surging export demand. Manual processes limited output to 4,500 packs per hour and created hygiene compliance issues for international markets.

Invensys Solution

Invensys Engineers designed and commissioned a fully automated, food-grade packaging line integrating high-speed SPM, hygienic conveyors, and robotic pick-and-place. The system handles dough forming, cooking, cooling, and final vacuum-sealed packaging in one continuous flow.

Key Technical Features

Stainless-steel, washdown-rated hygienic conveyors with quick-release belts
Custom SPM for precise dough sheeting, cutting, and stacking (servo-controlled)
6-axis collaborative robots with food-grade end-effectors and vision guidance
Inline weight checking + metal detection with auto-reject
SCADA system with real-time OEE dashboard and traceability to batch level
Fully compliant with FSSAI, HACCP, and EU food safety standards

Measurable Results

Throughput increased by 68%(4,500 → 7,600 packs per hour)
70% reduction in manual labouracross three shifts
Product consistency improved to 99.7% (zero weight variation complaints)
Zero contamination incidents since commissioning
ROI achieved in 8 months

Products & Systems Delivered

Special Purpose Machine + Industrial Conveyor Systems + Process Automation (Hygienic Packaging Line)

Proven Results. Trusted by Global Automotive Leaders.

Client Voice

Invensys transformed our packaging from a labour-intensive bottleneck into a high-speed, fully traceable, hygienic line. The system runs 24/7 with outstanding reliability and has helped us capture new export markets.