In the factory of PT Surya Food Group on the outskirts of Surabaya, Indonesia, the rich aroma of coffee and the sweetness of coconut milk are intertwined. On four parallel packaging lines, more than ten products such as instant coffee, coconut crisps, and ready-to-eat durian are speeding down at a speed of 150 bags per minute. Agus, the workshop supervisor, stared at the newly put into production silver equipment and smiled to his visiting colleagues: "This set of 'Transformers' has completely changed our production rhythm."
As a leading food company in Indonesia, Surya Group has long been trapped by the typical contradiction of Southeast Asian packaging machine demand - it must not only cope with the fluctuation of orders for multiple categories and small batches, but also meet the strict standards of halal food certification. The original equipment needs to be frequently shut down for line change, and a single switch takes up to 4 hours, resulting in a waste rate of more than 35% of production capacity. "When the customer asked to deliver 5 new packaging products within three days, we had to refuse," said Linda, the purchasing director.
After introducing ply-pack's modular packaging system, the technical team completed the equipment transformation in just 72 hours:
· Infrastructure: Adopts corrosion-resistant stainless steel body, adapted to the high temperature and high humidity environment in Southeast Asia
· Functional module: Equipped with 6 sets of detachable metering heads, covering powder, granules, paste and other material forms
· Intelligent control: Preset 22 packaging parameter combinations to achieve "one-click production change"
On the coconut crisp packaging line, the engineering team specially designed an anti-static module to solve the problem of coconut crumb adsorption; the durian production line is equipped with a negative pressure deodorization system to avoid odor cross-contamination. According to the production report, the equipment switching time was shortened to 18 minutes, and the order response speed increased by 4 times. "The most surprising thing is that the consumable loss rate has dropped from 12% to 3.5%", Agus pointed to the real-time updated intelligent operation and maintenance platform screen, "The system can automatically calculate the optimal sealing temperature, and even the waste of scraps is calculated clearly."
ply-pack's localized service team became the key to the success of the project. When the equipment suddenly issued a conveyor belt jam alarm, the engineer at the Jakarta service station used AR remote guidance to guide the on-site personnel to complete the troubleshooting within 10 minutes. "They even pre-installed the Indonesian operating interface in the equipment," Linda showed the localized menu on the control screen, "This kind of detail is the real 'Southeast Asian customization'." The setting sun sprinkled on the silver-gray fuselage through the factory skylight. Surya Group CEO Hadiel picked up a bag of coconut milk powder that had just come off the production line: "Now we can accept orders for children's snacks and catering large packages at the same time, which was unimaginable before." With the second batch of modular equipment entering the site for commissioning, the group is planning to expand its product line from the current 18 categories to 35 categories, aiming to seize 15% of the Southeast Asian snack food market.
