Smoked Fish Business Upscales With Automation

Challenge

Hardy Buoys Smoked Fish, a Canadian smoked fish producer supplying major grocery chains, faced significant operational challenges as demand for its products grew. Prior to automation, the company relied on a largely manual packaging process that required a large workforce making it difficult to scale output. Compounding this, the facility experienced persistent labor shortages, especially on the plant floor, and struggled to recruit workers despite high unemployment rates. As demand increased, Hardy Buoys was forced to reduce some orders, limiting its ability to expand customer relationships and meet market needs.

Solution

To address these hurdles, Hardy Buoys partnered with PLAN IT Packaging Systems to introduce automation into its packaging line. The core of the solution was an automated bagging line featuring:

• Semi-Automatic Multi-Head Scale: This replaced much of the manual weighing previously done by hand, improving consistency and throughput.
• RotoBagger System: A pre-made pouch bagging machine with multi-head weighing, a platform, and a sanitary washdown inclined conveyor to automate the transition from fill to bagging.

By selecting a system capable of handling far more volume than existing production able to support up to 10,000 packages per day, Hardy Buoys positioned itself for both current and future growth.

Implementation

The implementation involved installation of the RotoBagger line and training for plant operators. Although the COVID-19 pandemic delayed the initial setup by a few weeks, the line was successfully integrated into operations with support from Plan It Packaging’s technicians. Operators received two phases of training primary equipment familiarization and formal set-up procedures, enabling them to quickly operate and maintain the new system. Minor challenges such as incorrect bag sizing were resolved with Plan It’s responsive service and adjustments.

Results

The transition to automated packaging delivered measurable benefits:

• Reduced Labor Costs: The automated line cut labor requirements from 14 people to just six for the same output level, saving approximately $3,500 per week in labor expenses.
• Increased Capacity: The equipment’s high capacity allowed Hardy Buoys to target up to 10,000 packages per day, helping eliminate previous bottlenecks and support business growth.
• Improved Scalability: Customers reacted positively to the expanded capability, with co-packing clients increasingly willing to partner with Hardy Buoys due to its enhanced production capability.
• Operational Flexibility: The line enabled the company to maintain inventory and meet peak demands, such as around the holiday season far more efficiently than before.

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