Case Study – Supporting a National Cheese Producer with Complete Forming Set Solutions

A national cheese producer recently needed to upgrade the forming sets on their existing packaging equipment. They were already running Doypack VFFS forming sets for grated cheese and HFFS (horizontal form fill seal) flow wrappers for block cheese, but their existing forming equipment was wearing out and becoming increasingly difficult to maintain.

After comparing suppliers, they chose BagForm based on three things that mattered most to them: lead times, cost, and consistent build quality.

Survey and Design

We began with a comprehensive survey of their equipment to ensure every forming set would fit their existing VFFS machinery. From this, we produced designs built to an OEM-plus standard, enabling us to manufacture equipment that was efficient and suited to the daily demands of cheese production.

This included:

  • Doypack VFFS Forming Sets for grated cheese

  • HFFS Flow Wrappers used on their block cheese lines

  • Additional Spare Shoulders to help manage wear and reduce downtime

Reducing Downtime with Spare Shoulders

The shoulders on forming sets take the most wear, and when one fails, the whole line stops. Previously, the customer didn’t keep spares on site, so changeovers took much longer than necessary.

By supplying spare shoulders matched to their forming sets, a worn shoulder can now be replaced in under an hour. This will reduce unplanned downtime and makes maintenance planning much easier.

A Complete Forming Set Service

From the initial survey through to design, manufacture and delivery, BagForm provided a complete forming set service that fitted straight into the customer’s existing lines. One of the key requirements for this project was speed, as the customer needed the forming sets delivered quickly to keep their upgrade schedule on track.

As all the design and manufacturing are handled in-house, we were able to turn around the forming sets and spare shoulders faster than they had previously sourced from their existing supplier. This allowed the upgrades to go ahead without extended downtime or disruption to production. One of these upgrades included double chroming the shoulders on the forming sets, ensuring longevity in the demanding production conditions and environment.

Alongside the technical work, we also shared practical advice based on more than 40 years of experience in forming set design and packaging equipment. This helped the customer make confident decisions about what they needed, how to manage wear and how to plan for long-term use of the equipment.

Once the forming sets were installed, we continued to support the customer to ensure everything was running to their standard. That included follow-up checks, guidance on shoulder changes and straightforward aftercare whenever they needed it.

The result is a more reliable setup, shorter changeovers and a maintenance routine that is easier to manage.

If you are looking to refurbish or upgrade your VFFS forming sets or HFFS flow wrappers, BagForm can support you from survey through to installation, with quick turnaround times and long-standing industry expertise.

 
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