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Karsten UK

Updated: Jul 20, 2021

The Client: Karsten UK

The Karsten Group supplies a range of the best seedless table grape varieties available in the world to the UK’s major retailers. Karsten UK was established in 2005 as the distribution service provider of The Karsten Group in the United Kingdom and Europe

The Challenge: Adapting to supermarket packaging changes

Due to a supermarket packaging change, Karsten UK were looking for a reliable high speed heat sealing machine which provided great efficiencies.

Having already sourced their pre-printed film and to avoid any redesigns and additional costs PA accommodated Karsten's existing film and designed the new tool around the existing film format.

Karsten purchased a high speed twin lane heat sealing machine from Packaging Automation.

The Result: Greater efficiency and reduced unplanned downtime

The introduction of the tray sealing machine has allowed Karsten UK to upgrade their packaging from flow wrapping to heat sealed punnets providing them with cost and environmental benefits combined with greater efficiency and minimum downtime. The new line gives them a consistent seal on all packs and Karsten produce over 140 packs per minute consistently in production.

Karsten are now benefiting from PA’s unique pod tooling system, reducing unplanned downtime by up to 90%. The ingenious top tool comprises of a host plate and a series of single impression removable cartridges to enable continued operation during repairs, routine maintenance and breakdowns.

To save on critical production downtime, tool changeovers on the tray sealer can be done manually in less than two minutes as a result of an inbuilt tool loading system. Tool warmups are 36% quicker as a result of using silicone coated heater mats. The quick release cutting blades on the tools allow for replacements to be changed in seconds and spare cartridges can be supplied to enable full capacity operation at all times at minimal business investment costs.

The HMI screen is easy to operate with user-friendly controls and a display that provides clear reporting to the operator and an inbuilt manual function. Different languages are also available through a simple selection for various operator nationalities.

The machine has its own internet connection allowing the PA systems team to dial in to support Karsten at any given time 24/7.

Karsten UK commented:

“Choosing PA was an easy decision, we had to make our film work, and so with the help of the PA team we settled on the twin lane as they could design the tool to fit our film. The machine is very easy to use and PA went out of their way to get us the setup we needed to make it simple. PA are always there when you need them. I would without doubt recommend PA to anyone looking to tray seal.”


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