Category: News
A small specialist flapjack producer in a quiet corner of Devon has been able to increase production and improve product quality following the installation of one of Western Mechanical Handling’s ultrasonic cutting cells.
History
Flapjackery was started in 2015 by Carol Myott and Sally Jenkin who wanted to recreate the flavours of homemade flapjacks of their childhoods to sell through local markets and food festivals. From the start their products were a huge hit and they quickly outgrew their domestic kitchens and moved into a commercial kitchen in Tavistock, Devon. Soon after they opened their first shop also in Tavistock. From there Flapjackery have grown and expanded to open 14 stores across the Westcountry, plus online sales alongside festivals and food fairs across the UK.
Increased Production
In order to keep up with production a small amount of automation was needed to maximise throughput from the small workforce. The installation of a WMH ultrasonic cutter in 2022 has enabled production to ramp up to 4000 pieces of flapjack per day. Removing one of the hardest parts of the process, cutting the baked slabs of flapjack into retail and portion sizes pieces. A job that took over 2 hours by hand, can now be done in 40 minutes. With the assistance of the automated cutting unit, operators are free to carry out other tasks alongside loading the cutting cell.
Increased Quality
Hand cutting flapjacks by eye gave variation to the finished product. The use of WMH’s ultrasonic cutter ensures every piece is cut to perfection with sharp crisp edges. Even where recipes include chocolate toppings and those with large fruit and nut inclusions. The look of the finished product cements Flapjackery as a luxury brand with attention to detail across their offering.
The compact WMH cutting cell fits into a footprint a little larger than a standard pallet and needs electrical and compressed air supplies to operate. Operators load and unload the unit via the interlocked front access doors and use the HMI to start the cutting process. The cutting area is locked for the duration of the cutting cycle.
Flexibility
When originally supplied, the cutting cell was programmed to cut three sizes of flapjack. This has now been added to as Flapjackery’s, award winning, products have developed from purely retail to corporate and special occasion sizes. The unit also has a scoring programme for slabs for catering and food service customers. Operators use the touchscreen HMI to pick their product flavour and cutting configuration.
The Future
WMH continue to support Flapjackery through addition of new menu items as they expand their flavours and configurations. Also by providing onsite support maintenance and spares. WMH looks forward to continuing to see Flapjackery expand and grow. We hope to be able to support them on their journey.