Lonypack Global incorporated Ultimaker 3D printing solutions to optimise its food packaging process optimise the production process, using Ultimaker 3D printers in consultation with Sicnova and Kimya 3D printing material. This case study highlights that 3D printing technology saves costs and reduces delivery times.
About Lonypack Global
Lonypack Global S. A. is a company with 25 years of experience in the meat and cured dairy slests sector. It obtains the highest quality certificates and has boneless, sleed and packaged lines at its plant in Villacastín, Segovia. At the beginning of 2022, the company became interested in including 3D technology in the plant in order to optimize its production process, and it did so thanks to Ultimaker’s 3D printers and Kimya filaments.
Achieving greater self-sufficiency and cost savings
Lonypack began investigating 3D printing in early 2022. Their goal was to create new component designs that would improve the manufacturing process. This would allow the Spanish company to make these improvements in its cutting-edge plant in the most cost-effective and customizable way possible.
The first challenge was locating manufacturing materials that were food-safe. Lonypack needed a way to regain control of the supply of replacement parts and the manufacture of components for its boning, slicing, and packaging lines in order to increase self-sufficiency and resilience.
“3D printing has allowed us to create parts such as cutting edges, picker combs, turning mechanisms, and sprockets for our robot arms and cutters at a cost of up to 70% less.”
– Román Velasco, Director of Industrial Engineering, Lonypack
Food-safe parts printed with Kimya PETG-S filament
Lonypack began investigating the use of Ultimaker S5 3D printers to create customised parts for its production line. They did so by following the advice of Sicnova and its reseller Cosomo 3D, who assisted them throughout the technology implementation process.
Lonypack chose the Ultimaker S5, a machine that brings industrial capacity to a desktop size, because of its precision and dependability. Furthermore, they chose the PETG-S filament from the leading material brand Kimya because its blue colour indicates that it is certified safe for food contact.
3D printing technology saves costs & reduces turnaround times
The new design solutions were implemented from the beginning. Parts such as cutting edges, line comb pickers, turning mechanisms, and sprockets were created by Lonypack for up to 70% less than they were previously.
Lead times were also reduced by 70% when compared to previous deliveries.
During slicing, the cutting edges protect the blades. The portions to be packaged are picked up by the picker combs. The turning mechanism transports the portions to empty trays included in the package. Without Kimya’s assurance that the parts printed were food safe throughout the process, none of these cost savings in the operation of the robot arms and slicers would have been possible.
Lonypack’s first experience with 3D printing has been a great success, as Román Velasco explains, “It’s just a matter of time before other food companies incorporate these solutions into their production processes. And in the future, they will be an essential part of the plants.”
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