EastPack Washer Road Case Study

Objectives

The goal for EastPack Washer Road was to enhance production efficiency, minimise downtime, and increase throughput to handle peak-season demands. As one of New Zealand’s largest post-harvest operators, EastPack sought a reliable automation solution tailored to their specific operational needs, ensuring consistent performance and long-term scalability.

The Problem

EastPack, a leading packhouse, faced significant operational challenges with their manual bagging and packing processes. Utilising up to 25 labour units, including supervisors, manual bag placing often resulted in inconsistent placement, which disrupted downstream filling and closing operations. The variability in speed among manual packers further compounded inefficiencies, with absenteeism directly impacting throughput targets.

In addition, the reliance on ageing equipment limited EastPack’s ability to scale with growing production demands, causing bottlenecks during peak periods. Frequent maintenance requirements and unplanned downtime disrupted operations, reducing overall output and productivity.

Punchbowl Automation provided a transformative solution by integrating state-of-the-art automation technologies. With innovations like the Speediplast and Speedyfold machines, EastPack achieved consistent, precise bagging and sealing at speeds of up to 25 and 20 boxes per minute, respectively​​​. These systems featured user-friendly touchscreens, remote servicing capabilities, and reduced labour dependence, leading to improved operational consistency and cost savings​​.

The result was a streamlined process with enhanced throughput, minimal maintenance requirements, and a significantly lower cost of ownership​​. This partnership exemplifies how modern automation can resolve labour-intensive challenges while positioning businesses for sustained growth.

The Solution

Punchbowl Automation partnered with EastPack to revolutionise their packing operations with a tailored bag-inserting solution. By integrating five Speedyplast machines into the production line, EastPack experienced a dramatic reduction in labour requirements and a significant boost in consistency, speed, and overall efficiency across their packhouse.

Understanding EastPack’s high-demand operational environment, Punchbowl also implemented a proactive maintenance programme, shifting the focus from reactive fixes to preventative care. This customised service offering ensured minimal downtime and optimised machine performance during peak packing seasons.

Through the integration of advanced technology and optimised workflows, Punchbowl Automation delivered a solution that not only improved throughput and reliability but also positioned EastPack Washer Road to handle increased demands with confidence. This strategic partnership laid the groundwork for sustainable growth and operational excellence.