CASE STUDY
Bar Line Production Area Improvements
Nutrition Group are manufacturer of vitamins, minerals, and supplements, supplying the VMS, Sports Nutrition, Animal and Beauty sectors. Having installed a new bar line, they encountered several challenges within the production area and required options to improve facilities.
The Challenge
Nutrition Group had installed a new bar line and had several challenges within the production area. These included: • Washroom leak affecting areas of production • Changeover and set up challenges • Inconsistent hygiene results. Protolan were asked to review these challenges and present choices detailing resolutions and improvements.Delivering Success
Protolan developed several options for washroom improvements including the flow of personnel and product. We also investigated options to modify the building to stop water ingress into other areas and improve the process of washing equipment. Protolan delivered detailed drawings showing re-design for this area and options available. The set up and changeover procedures were developed by spending time on the production line, observing how Nutrition Group were completing the tasks, reading supplier manuals, and applying their operational knowledge. To streamline and ensure effectiveness, Protolan developed a dynamic changeover matrix. This helped Nutrition Group identify the types of changeovers required enabling them to plan more effectively. The matrix was designed to easily add additional products as they were developed, guaranteeing the matrix was consistently up to date. The hygiene procedures were written alongside the changeover improvements to ensure consistency. The materials and current processes were observed and written into the same format as the changeovers. Product and industry knowledge were used to analyse the results to make improvements to their processes. Protolan worked closely with the teams on site and used our experience within the food industry to develop procedures and a way forward that would deliver results for Nutrition Group.Services Employed
Project Management
Process Analysis and Design
Technical Knowledge
Operational Support
SOP Writing
“Having worked alongside Protolan previously installing a liquids bottling line, we chose James and his team to assist because we knew we could rely on their knowledge and expertise to deliver the right result. The hygiene and changeover process improvement project was delivered professionally and on time. I would not hesitate to recommend Protolan and will definitely use them again in the future should the need occur.”
- Richard Greathead, Chief Executive
Nutrition Group PLC
“The Protolan team have been an important part in the success of our recent, complex projects. They are a dedicated partner who are responsive, client-conscious and own a wealth of food manufacturing knowledge. Protolan’s project team worked closely with our internal team to deliver a multifaceted project, providing innovative solutions to ensure best practice across the factory. They show great diligence and flexibility when faced with project challenges. I look forward to a continued relationship with Richard and his team and would not hesitate to recommend them.”
- Gary McEvoy (General Manager)
Bakkavor Texas
“I have worked with Protolan over numerous years and am more than happy to recommend them to deliver our projects. They understand our business and are skilled in utilising their extensive food manufacturing expertise to support our complex needs. They have the foresight to identify possible issues and give solutions that are effective, offering genuine insight for our business. The Protolan team provide an experienced, knowledgeable and straight-talking resource. It is a pleasure to work with them.”
- Simon Wood (Chief Engineer)
Hotel Chocolat
“Protolan show great understanding of the food industry. They have the leadership, food expertise and project management skills to understand our challenges and familiarise themselves with our business objectives. Their concise communication provided us with a clear view of the issues and challenges of the project, providing us with a tangible project plan and a successful scheme.”
- Sally Mitchell
Saladworks
“Having worked with Protolan on several major projects, I am always impressed by their expertise within the food industry and positive attitude. They fully integrated into our team and that of the wider business, understood our challenges and delivered a tangible plan guided by solid project management and engineering practices. They have been a pleasure to work with and we will continue to work with them on future projects.”
- Jason Kelly (Head of Operations - Core Produce)
Morrisons
"Having worked with Protolan on previous projects, Revolution Foods had no hesitation to engage them to collaborate with us on a new project in challenging times.
Protolan work with us in complete partnership, ensuring they understand the scope of our requirements and the challenges involved. Thorough, responsive, and professional, Protolan ultimately brought our project to a successful conclusion.
I would have no reservation in recommending Protolan."
- Jose Morales Senior
Director of Operations Revolution Foods