DS Smith has increased throughput on a wine packaging line at the Delhaize winery in Belgium from 1,500 to 1,900 packs per hour, a gain of 400 packs per hour, or approximately 27%. The project combined a redesign of the corrugated packaging with changes to the machinery processing it.
Against a background of pressure on retailers and manufacturers to increase productivity and maintain product availability, Delhaize sought additional capacity and efficiency within its existing production process.
Packaging and machinery designed together
Rather than sourcing the cardboard packaging and machinery separately, DS Smith designed and built a dedicated forming machine engineered for Delhaize’s bag-in-box packaging format and production requirements.
The approach aligned the corrugated packaging and machine performance from the outset. This improved stability and efficiency across the manufacturing process, enhanced pack quality and eliminated almost all interruptions on the production line.
The line became more reliable and required fewer operators, while making more efficient use of warehouse space. Storage capacity increased from 5,000 to 6,000 packs per storage location.
“What sets DS Smith apart is its ability to optimise both packaging and machinery as a single solution,” said Hervé Louis, Production & Technical Manager at Delhaize, Belgium.
“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. I am impressed with DS Smith’s service levels,” Louis added.
Improving the performance of the entire system
Kim Radelet, Sales Marketing & Innovation Director Central EMEA at DS Smith, 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.”
“That is where real value is created: not in optimising individual components, but in improving the performance of the entire value chain,” Radelet added.
Ahold Delhaize’s store formats include Delhaize, Maxi, Albert Heijn, Albert, Food Lion, Gall & Gall, Mega Image, Alpha-Beta, Hannaford, Stop & Shop and The GIANT Company, covering traditional supermarkets and online shopping.
DS Smith’s target-led sustainability strategy includes supporting the transition to a circular economy and providing circular solutions to customers worldwide.
