Baskin-Robbins finds control through custom fillers

Dairy Foods, June, 2002

Baskin-Robbins ice cream is known for its inclusions: ribbons of velvety fudge, marshmallow pillows, nuts and swirls of seasonal flavors. Order a Pralines & Cream[TM] single scoop cone in Sydney, Australia; Seoul, Korea; Seattle, or any of the 5,500 Baskin-Robbins stores around the world, the experience should be the same. Consistency of product is an essential element Baskin-Robbins must deliver to both franchisees and customers.

Baskin-Robbins co-packs its products with more than one supplier, making the need for a consistent filling solution all the more important. The 24 million gals of ice cream processed each year in 14 plants is required to meet strict quality control standards, as well as a host of aesthetic considerations.

Until recently, the company hand-packed its 3-gallon straight wall "ice cream store" containers. A few of the 14 plants were partially automated with a not very user-friendly hand-rotated 3-gallon filler, but not having a reliable automatic filling solution resulted in high levels of product rejection by the company Peter Hopps, v.p. of global manufacturing, distribution and technical services for Baskin-Robbins sought a more efficient, reliable and affordable way to package Baskin-Robbins signature offerings while attending the International Food Show in Chicago.

There, he became acquainted with the T.D. Sawvel Co. Model 702 three-gal bulk filling machine. Designed and developed at T.D. Sawvel's headquarters in Maple Plain, Minn. the high-volume, low-cost automatic volumetric bulk filler features continuous flow, volumetric bottom-up[TM] fill, automatic infeed, filling and lidding, SS304 construction, and simple electric pneumatic control circuit.

Botom-up[TM] volumetric filling is a proprietary process developed by T.D. Sawvel. Each container is raised up to meet the incoming product. The ice cream then pushes the container/fill elevator back to its original position. This process eliminates air pocket formation, as well as removes air pockets coming from the freezer or ingredient feeder (major considerations when dealing with the high number of inclusions used by Baskin-Robbins). Every container is filled to the same volume, doing away with over and under fill complaints. Weight is controlled by the freezer overrun.

Hopps was impressed.

"We were looking for a solution that could turn the tubs, could be more consistent, give a proper fill, was automatic, and was easy to maintain," he says. "It met all of our requirements." And more, as it turned out.

"We met Tom Sawvel. He just understood what we were talking about," Hopps recalls. "He engaged in the process of helping us to deliver the most consistent product possible. That really impressed us. Now, we are working with (T.D.'s new president) Troy Sawvel, and he is just as engaged with the process."

The 702 series is now standard equipment in l1 of Baskin-Robbins' 14 plants internationally.

Hopps has advice for those seeking to automate. "Know your product. Know what you want from your product and what you want it to look like. If you have high production needs or use a lot of inclusions, the T.D. Sawvel model 702 is really an optimum equipment choice to make."

How has the equipment worked out for Baskin?

"The bottom line is this equipment has enhanced productivity across our global operations. Greater productivity results in greater profits," Hopps concluded.

T.D. Sawvel Co.

877/488-1816

www.tdsawvel.com