“TNA’s case packing systems has enabled us to improve operational efficiency, redistribute manpower and future-proof our operations.” Andrew McManus, Manufacturing Manager – Majans
Building on its ongoing relationship with TNA solutions, Majans leveraged the all new tna ropac® 5 technology to automate its case packing operations. At a capacity of 200 bags per minute, and featuring a bag conditioner, case packer, case erector and checkweigher, it is the fastest case packing system on the market today, with the smallest footprint. Since its deployment it has helped to deliver an impressive 140% throughput increase in just 12 months.
Established in 1984, Majans produces over 2 million cases of snacks each year across a range of 53 products. The company has ambitious growth plans, and with a tough labour market and volatile supply chains to navigate, it needed a trusted partner to help increase throughput and reliability, enhance uptime and mitigate risk. Manufacturing Manager Andrew McManus had already experienced TNA solutions in operation during his time at Mars and was reassured when Majans’ owner, Kam Raniga, selected the company to help future-proof operations.
“I’d seen TNA baggers working perfectly after 40 years of service, and I knew we were on track when we made the decision to partner with TNA at Majans. With a TNA flavouring system and tna robag® baggers already in place, we knew we would benefit from the interchangeable aspects of a TNA solution for case packing – particularly from an electronics perspective, and also the consistency of the HMI interface for our technicians. Introducing tna ropac® 5 systems has enabled us to improve operational efficiency, redistribute manpower and future-proof our operations as we look to continue our growth path.”
Majans currently uses around 70% of the tna ropac® capacity of 200 bags per minute, but through working with TNA solutions the company has ensured that future increases have been firmly factored into the equation. Since its introduction in February 2023, throughput performance has increased by 140% and uptime by 15%. From a sustainability perspective, the tna ropac® 5 is also able to accommodate the company’s plans to move to paper-based packaging in 2024, supporting its sustainable development plans without impacting production speeds.
“Just five years ago, Majans regularly had between 28 and 35 people on a single shift, bagging, mixing and case packing,” continued Andrew. “Today, with the help of TNA solutions, that same factory operates with just 10-11 people per shift at outputs up to 6.9 times greater than before the automation process began. Casual jobs have been transformed into stable, full-time employment contracts, and technicians and maintenance crews have also been upskilled to effectively service and support these systems at a higher technology level.”
Speaking about the strategic partnership between the two companies, Thiago Roriz, Chief Operating Officer at TNA solutions said: “In recent years, we have further strengthened our market leadership through sustained innovations, delivering true business value to our valued customers, such as Majans. We are extremely grateful to Majans for choosing us as their trusted partner, to support their goals as they focus on their expansion strategy.”
To read the full case study on TNA solutions’ partnership with Majans, click here.
If you would like to speak with TNA snack experts, please visit the company’s stands 242 and 341 at the SNACKEX show from 19-20 June in Stockholm, Sweden.
