In 2019, The Big Biscuit Company ordered their first IPS-8BT pouch filling line from Intamac Packaging Systems. Fast forward two years and we are back at the factory on the day they are having their fourth Intamac machine installed, a twin head linear weigher and bulk bag filler. The Big Biscuit Company founders, brothers Alex and Leo Baker, are on site to discuss how their business has changed since their first machine arrived.
On arrival at their manufacturing facility the difference from two years ago is obvious. The factory is still clean and well laid out, but now there are a further three machines on display – each one busily packing dog treats to meet customer’s demands. The range of equipment now includes three IPS–8BT’s with multi-head weighers and conveyors, one flow wrapper and the new bulk bag filler. Each machine is fitted with a versatile Norwix ink jet printer, ready for easy barcodes and date printing.
The Big Biscuit Company has grown and now has 35 full time employees and a steady stream of agency staff packing on site and, with an estimated additional 32 million new pet owners in the UK and a 30% growth in dog ownership, this trend looks set to continue. They have had to adapt quickly to meet market demands and be agile enough to make the essential business changes needed to grow in line with the market. Alex Baker is excited by how the business has developed.
“The first Intamac machine was basically a catalyst for our business. Two years ago we were packing fifty thousand packs a month, now this has reached half a million and we are continually adapting and changing. Our business has tripled since that first machine.”
He continues, “The fast availability of Intamac equipment helped us to react to the growth in the market and demand from customers. We ended up ordering our second 8BT in January, it was installed in February and has been running for 16 hour shifts ever since, and we have another one on the way!”
The Big Biscuit Company have a unique business model where they are involved in the entire product development process. The customer shares their concept and they then design, bake, pack and dispatch the product. They are continually looking to evolve and innovate and recently partnered with a digital pouch printing company. This enables them to offer short runs and create an entry level product at a competitive price. This is popular for customers as it means they can test the market with new packaging styles and options without the large outlay that this development normally carries.
Research and development is key to Big Biscuits growth and the purchase of an Intamac flow wrapping machine has enabled them to offer more options to customers. Traditionally, larger items, such as dog chews, were packaged using a bag in a box. This tends to use large volumes of packaging and is bulky to ship. Intamac’s engineers and The Big Biscuit Company’s R&D team worked closely together to find a solution for flow wrapping the chews.
After much trial and error they can now pack them in either film or paper, with the added benefit of reducing the amount of packaging required by 50%. Customers are also delighted with this development, as you can pack 32% more product, use less material and still have plenty of scope for the marketing and branding opportunities that ensure the packaging stands out on the shelves. For Alex this has been a key investment,
“The flow wrapper is another machine that has revolutionised our business. We were looking at ways to pack dog chews and Intamac suggested this option.”
He explains, “We have found that the machine build quality is high, particularly for what was a relatively inexpensive piece of kit. It has also allowed for further innovation and we have worked closely with Intamac’s engineers to find better ways to pack the dog chews. It’s a great alternative for our customers, who are really pleased with this solution, and it has made us more competitive in the market.”
Tom Poston from Intamac Packaging Systems has worked closely with Big Biscuit since the first machine was purchased and it is clearly an important relationship for him.
“I really enjoy working with the Big Biscuit team. Not only are they expert operators of the machinery but they are always looking at new ways of using the equipment to make it work even better for them.
“Whenever I visit the site I am always waiting to see what they are doing next and how they have adapted the machinery to fill different shaped packaging or trialled new materials, it’s a constant learning curve.”
On a more recent project Big Biscuit have been working closely with Intamac to see how a twin lane linear head weigher could be specifically adapted to fill larger capacity bags. They are aiming to expand their offering to the pet food market and were looking for a way to pack big bags of dog food, up to 15kg.
The system was created by using a steep conveyor to drive the product up to the weighers and then to release into the bulk bags. This new machine will open up new business areas and allow for further expansion, creating innovation and more opportunity for customers working in the pet food market.
Alex finds Intamac’s machinery to be incredibly versatile,
“Often the equipment is used for more than the original purchase intended. We have found that, with a few alterations, the machine can be adapted to pack into a variety of packaging. It also worked well with the different types of environmental packaging we now use and has managed to pack into an array of films, paper pouches, odd shapes, odd sizes.”
Looking to the future the company is founded on a strong ethos that believes in improving animal welfare. The close knit team are all fundamentally animal lovers and pet owners this helps drive the business forward as they are looking to enhance their products to make them even better for the ultimate end consumer.
“We are driven by delivering quality products for animals, this means we are always improving our ingredients, range and packaging. We have formed a strong partnership with Intamac which is helping us to achieve our goals. They have made a big difference to the business and always offer great support.”
To find out how we can help you improve your packaging processes, talk to us today by calling 01420 593 682 or make an enquiry here.
