Improving productivity and efficiency in dairy product packaging

Curd packaging made easy by Samarpan Fabricators and Trio Motion

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Curd must be normally stored at 4°C to 5°C. The storage area needs to be clean to avoid cross-contamination

Most Indian meals are incomplete without a ‘dahi,’ or traditional Indian yogurt or curd – a powerhouse of essential vitamins and minerals, which is highly nutritious, cooling, and light. Product packaging is an essential part of curd manufacturing. It not only protects the food from any physical or chemical damage but makes handling convenient. The Indian dairy industry places its trust in packaging solutions from Samarpan Fabricators Private Limited for a single source, manless packaging, and cartoning curd packaging line. The Samarpan Group provides these high-speed, reliable solutions, completely automated by Trio Motion Technology India.

Samarpan’s machines are used in dairy factories in India and abroad providing curd packaging solutions using high-impact polystyrene cups. These cups are weather-resistant, malleable, recyclable, and FDA-approved. “With more than four decades of experience, Samarpan has ushered in a revolution in the packaging industry by introducing Flexible Packaging concepts. These concepts have drastically changed the quality of packaging in India. Samarpan offers a wide range of machines for various industries and enables its customers to pack milk, ghee, vanaspati, edible oil, condiments, detergents, pesticides, coffee, tea, and shampoo among many other products,says Bhavin Soni, general manager, Marketing, Samarpan Fabricators. “Realizing the necessities of packaging in India, Samarpan, over decades, has collaborated with leading European companies. It offers packaging machines that allow it to deliver machines to pack varying quantities ranging from 10 grams to 5 kilograms,he adds.

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Bhavin Soni, general manager, Marketing, Samarpan Fabricators.

Stringent packaging norms for curd

Curd must be normally stored at 4°C to 5°C. The storage area needs to be clean to avoid cross-contamination. It must always be stored away from sunlight or UV light to maintain its aroma and flavor until final consumption. To prevent the curd from absorbing moisture and unpleasant odor, it must be packed in airtight containers. All these stringent norms must be met while packaging curd on machines in the dairy industry. “Samarpan has immense experience and process know-how to make them trendsetters in this packaging segment. We are proud of the fact that our customers come to us with a product for packaging. After understanding the challenges and complexities, we develop a complete solution that exceeds their requirements. We offer total packaging systems right from concept, design, implementation to commissioning,says Bhavin Soni.

Filling to carton from a single source

Over the years, factories increasingly demand primary and secondary packaging equipment from a single source. This helps in achieving higher productivity, throughput, and less downtime. Samarpan’s Prestige-12k and Prestige-9k machines are continuous-motion high-speed curd cup-packing machines that enable continuous curd packaging without the need to stop the machine for filling and sealing. These machines are designed to run at 200 cups per minute and 150 cups per minute and have been successfully deployed at these speeds across various dairy cooperative unions and private companies. The machine is built to feed empty cups over a conveyor, followed by a station for the filling process and a station for placing aluminum foil for sealing. 

After sealing the filled cups, the conveyor moves the cups for cartoning. The continuous motion cup filling machine is equipped with an automated ‘Cleaning In Place’ CIP system with an automatic feeding system controlled through a touch screen to maintain hygiene standards as well as product feeding accuracy, respectively. Further, the filled cups are placed in cartons and are packaged using specific matrix structures such as 3×3 or 5×3 or as per customer requirement. The machine seamlessly adapts to the matrix structure as desired by the customer. The machine is equipped with all the necessary interlocks, such as no cup no fill, no fill no foil, no foil no seal, etc., to reduce the wastage of packaging material – thereby enhancing the operational efficiencies. The entire packaging line, from filling to the cartoning, is completely automated.

Trio motion controls with EtherCAT, the differentiator

Trio motion controllers are an undisputed choice for OEMs (machine builders) for packaging machines. They are equipped with advanced features, extremely reliable, and can be easily integrated into applications. “With Trio Motion Technology, we have been able to leverage the potential of our process know-how and mechatronic strength. Trio Motion controls can easily handle complex motion tasks, synchronize multiple axes, and precisely control the packaging process. Whenever I hear about Trio Motion Technology, the first thing that comes to my mind is technology supremacy,” says Jackson, general manager of Production, at the Samarpan Plant. “EtherCAT has been a game-changer for our packaging machines. The real-time deterministic technology, coupled with Trio Motion Technology, helps us stay ahead of the market, and our machines to operate at exceptionally high speeds,” he adds.

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Jackson, general manager of Production, at the Samarpan Plant.

Trio Motion controls and EtherCAT technology help Samarpan with a robust, high-performance, and future-proof solution for their packaging machines and lines. Precision plays a vital role in packaging machines to ensure consistent product quality and avoid wastage. “Our technology enables Samarpan to achieve higher productivity, flexibility, and reliability in their packaging operations. With Trio motion controllers, Samarpan improves accuracy and precision in their packaging machines and lines,” says Upendra Vanarase, managing director, Trio Motion Technology India.

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Upendra Vanarase, managing director, Trio Motion Technology India.

Technology supporting better working conditions

Conventionally, after primary packaging, the secondary packaging was handled manually by deploying a human workforce. Personnel were deployed in factories to place the packaged curd from the conveyor to the cartons in the desired matrix. As the speed of machines have increased over the years, it was technically inhuman to expect manual operations in secondary packaging. “Samarpan was quick to notice these challenges and working conditions of the human workforce. We developed a solution for combining the primary and secondary packaging so that the human workforce can be deployed for other tasks, improving their workplace,says Jackson.

Achieve more together

Collaboration is a key ingredient for our success. We can provide advanced machines for primary and secondary packaging owing to our long-term partnerships with our customers and vendors. Apart from the technology and automation expertise, with Trio Motion Technology India, we got to work with the best-dedicated team that helped us build rugged, high-performing machines. Our collaboration goes back 10 years, and we are extremely delighted to have Trio as our automation partner,” says Jackson. Samarpan, in its continued search for perfection and innovations, has developed machines to suit the packaging needs of liquids, semi-liquids, semi-solids, and solids. 

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