I am moving premises shortly and want to build the ideal layout for my production and packaging that will also be BRC compliant.
The last "food" stage will be lifting biscuits off trays and onto the flow wrapper in-feed. The biscuits are wrapped individually.
The other end of the flow wrapper currently drops the wrapped biscuits into a box which is then carried out to the packaging area for counting into smaller boxes.
In the new premises, if I make a hatch for the flow wrapper, it could deliver the biscuits to the packaging area, but then the production room wouldn't be sealed.
If the flow wrapper is in the bagging area, I would be carrying unwrapped biscuits out of the production area for bagging.
What is the ideal layout for moving from finished biscuit to bagged biscuit?
I understand from your question that you are worried about hygiene.
Manual handling is the biggest source of contamination, but only as long as the products are not wrapped. I understand that you manually remove the biscuits from the trays and place them in the infeed of the wrapper. That is labor intensive (expensive) and requires good personal hygiene. There are alternatives but to discus these more information on the product, production volume and packaging material is required.
Separating the packaging from the production is simple.
Make a hole in the wall separating process and packaging and put the infeed through the wall.
Disadvantage of this set-up is that the operator has no direct contact with the personal feeding the biscuits to the wrapper.
Another solution: the discharge belt goes through the wall. Now operator and feeding personal have direct contact.
Always separate the area where carton is used; (erecting and loading cartons) from the primary packaging area. Carton causes carton dust and you have to assure that it cannot contaminate your product.
Avoid transporting products in cartons, that adds no value, but only cost. Use a simple belt to transport from the primary to the secondary and shipping packaging
If the biscuit is high end variety with chocolates and chunks, or enrobed, or encrusted you need special environment for packing. If the lay out is L type or H type you need to separate with production area with partition and Air conditioning.
If the packaging of normal biscuits like SD, HD or Crackers you can pack without partition after seeing that the biscuits are properly cooled and packed with wrapper. Then you can take the wrapped packets to any location for supplementary packs as per sku you decide.
My suggestion is what ever SKU you plan it is better to pack with primary and secondary packaging in same packaging area and tertiary packing (transport pack CBB) at different location to avoid breakages.
They should be separate but connected. H or L layout depend on the Size of area.
Your Question: How are the two connected?
I told you L type is great for smaller areas and H or I type (layout) Ideal for large area
biscuit plant layout design are
H Type is ideal for Large area and L Type for small area.
Thank you Parisa, is the packing section within the same room as the food production, or separate?
How are the two connected?