In February our long awaited brand new “Form, Fill and Seal” machine made it safely to its new home at our Yogurt Works. Installing the behemoth machine was no small task as it meant removing an exterior wall to our factory to get it in! After a month of installing, testing and quality inspections, the new filler is running like a charm, filling over 68 multi-packs a minute! With our former multi-pack filling machine we placed single cups at one end of the machine where they ran along a conveyor, were filled with product, were individually sealed with plastic film, and then were bundled into 6-packs with a paperboard over-wrap. The new “Form, Fill and Seal” machine begins with sheets of plastic which get pressed into a mold to form four six-packs of cups at a time. The six-packs are then filled with product and sealed with a sheet of lidding material.

This new technology, in addition to eliminating the paperboard over-wrap, also allows us to use less material in the plastic cup. By switching to this convenient design, we will eliminate over 500,000 lbs of packaging each year, preventing that material from ever reaching landfills. We’ll also eliminate the transportation of empty cups to our facility from the cup manufacturer, saving energy, and creating less air pollution.

Care to learn more about our packaging choices? Click here.