27 February 2025 //
At ADCO Manufacturing, we thrive on challenges that push the boundaries of conventional packaging solutions. Recently, one of our longstanding frozen pizza customers presented us with a request that, at first glance, seemed nearly impossible.
They needed an autoload cartoner capable of handling up to 350 flow-wrapped 7″ round pizzas per minute—a production rate that demands high precision and reliability. But that wasn’t all. The machine also had to accommodate a different product entirely: French bread pizzas. And it wasn’t just one style; the machine needed to handle French bread pizzas in three distinct configurations: single pieces and two-counts, with each presented in both stacked and side-by-side formats.
To make matters even more complex, the new machine had to fit within the same physical space as their older cartoner and indexer, meaning we had to work within tight spatial constraints. On top of that, the product supply was highly inconsistent, delivered by a single conveyor fed by three different wrappers. This variability in supply added yet another layer of challenge.
Their needs set the stage for an engineering solution that would not only push our creativity and precision but solidify our customer partnership.
Rising to the Challenge
For many companies, a challenge like this might signal a project to avoid. But our longstanding relationship with this customer meant we knew the stakes—and the potential for success—was high. Our team understood that while the request might seem out of reach, it was an opportunity to challenge our boundaries and deliver a solution tailored precisely to their needs.
Engineering a Custom Solution
Our engineers got to work, combining proven design with innovative modifications. The result was a custom smart pitch indexer integrated with an upgraded version of our SDBC cartoner. Key enhancements included:
- High-Speed Modifications: A five-head rotary feeder designed to keep pace with the high throughput.
- Extended Carton Magazine: A 10-foot-long magazine ensuring a steady supply of cartons.
- Electric Glue Guns: For precise and reliable sealing.
- Optimized Changeover: Engineered to handle five different carton sizes seamlessly.
- Washdown Construction: Featuring hex mesh stainless steel barrier guarding for easy and thorough cleaning.
This custom-engineered solution not only met the complex requirements but exceeded our customer’s expectations, reinforcing the trust and partnership we’ve built over the years.
For more details on our engineered solution, CLICK HERE to check out our CONCENTRiX® SDBC – Servo Auto Load Cartoner.
Leveraging Frozen Pizza Expertise
At ADCO Manufacturing, our deep-rooted expertise in frozen pizza packaging plays a pivotal role in our innovative solutions. With decades of experience supporting leading brands in the frozen pizza industry, we understand the unique challenges—such as product consistency, handling high-speed production, and maintaining product integrity under demanding conditions.
Our work on this custom cartoner project is a natural extension of that expertise. By integrating lessons learned from our frozen pizza solutions, we were able to design a machine that not only meets high throughput demands but also handles a variety of pizza products with precision. Our specialized knowledge in frozen pizza packaging and our engineering prowess is what sets ADCO apart as a trusted partner in the industry.
Exceeding Expectations and Looking Ahead
The successful development of this custom cartoner is a testament to what’s possible when innovative engineering meets real-world challenges. By focusing on precision, adaptability, and reliability, we were able to turn a seemingly impossible request into a robust solution that drives efficiency and supports our customer’s unique production needs.
At ADCO Manufacturing, every challenge is an opportunity to refine our technology and deliver solutions that empower our customers to succeed. We’re proud of our team’s ability to innovate, leveraging our extensive experience in frozen pizza packaging along the way, and look forward to tackling the next big challenge in packaging automation.
Have questions or want to learn more about our custom-engineered solutions? CLICK HERE to contact us or visit our website for more information.
Contributing Authors:
Clare Blodgett – Clareity Marketing
Colin Warnes – ADCO Manufacturing
Published:
February 27, 2025