Challenge and Outcome: Frozen Product Buffer System for Chocolate-Coated Fruit

Wrightfield supplied a bespoke buffer conveyor system for a chocolate-coated fruit processing facility, working in partnership with Starfrost. The system was designed to support the handling of delicate products such as chocolate-covered strawberries and raspberries within a frozen processing environment.

The core challenge was managing two conflicting process requirements. At the front end of production, the customer needed to maintain a continuous flow. The coating process involves molten chocolate, meaning any interruption could lead to product quality issues, waste, and inefficiencies. As a result, stopping and starting this part of the line was not an option.

However, at the packing stage, intermittent operation is unavoidable. Processes such as bag changes, reel changes, and label swaps require the line to stop periodically. Without a solution in place, these stoppages would force the entire production process to halt.

To overcome this, Wrightfield designed and implemented a buffer system positioned between the spiral freezer and the packing line. The system effectively decouples the two processes, allowing production to continue uninterrupted while providing temporary storage for product when the packing line is paused.

A key aspect of the solution was maintaining product integrity during buffering. As the product is frozen, it was essential to keep it within a controlled, low-temperature environment to prevent degradation. The buffer system was therefore integrated within the freezer section, ensuring that product quality was preserved throughout.

The result is a highly efficient system that balances continuous production with the practical realities of downstream packing, improving overall throughput while maintaining product quality.