Tofu King quadruples productivity with semi-automatic scale

Tofu King Ltd, a Birmingham-based producer of bean curd products (Tofu) for the oriental food market in the UK, has installed a Semi-Automatic Dataweigh (SDW) multi-functional scale from Yamato.

Yamato was selected because of its high quality sales and customer service and its ability to deliver a weighing solution that could be quickly set up and work ‘straight out of the box’.

Tofu King’s business has grown and owner Yan Lui saw the need to automate some of its processes in order to meet demand. Automating the packaging process to some extent meant that Tofu King could increase productivity.

“Yamato offered an excellent sales service.”

“We were able to go up to Leeds to see weighing and packing solutions in operation. Yamato was also able to visit us on site, review our issues and develop a space-saving, yet quick and accurate solution for our packaging needs.

“The machine could be installed and used on its own without the need to add other components that would take up more space on the factory floor.”

said Yan.

A Semi-Automatic Dataweigh (SDW) multi-functional scale was provided for portioning and feeding to the packaging area. The Dataweigh (SDW) is capable of reaching speeds of up to 30 packs per minute on retail packaged Tofu King products.

The machine was able to fit into limited space and was capable of working with other machines that Tofu King had in place.

Hygienic and waterproof, the Semi-Automatic Dataweigh is able to deal with both dry and marinated tofu products because the hoppers and conveyor belt can be easily removed when required for ease of maintenance and cleaning to ensure optimum hygiene.

Hygienic and waterproof, the Semi-Automatic Dataweigh was able to deal with both dry and marinated tofu products because the hoppers and conveyor belt can be easily removed when required for ease of maintenance and cleaning to ensure optimum hygiene.

The flexibility that Yamato’s equipment allows enabled Tofu King to offer more competitive deals to its clients, easily adjusting the machinery to suit the different products, weights and sizes required.

Yamato commercial operations manager Andrea Spencer said: “The process of packaging tofu products was done manually because of potential problems packing various weights of both dry and wet products which contain oil – chilli marinated tofu for example.

“This meant that the packaging process was slow, with a number of different stages carried out by hand. Restrictions on space also affected production.

“Tofu King really needed a machine that could be set up quickly and work ‘straight out of the box’. The solution also had to have the capability to alternate between wet and dry foods as well as the ability to handle both small retail sized packs (100 g) of product all the way up to bulk sized packs (4.5 kg). Space in the Tofu King premises was also an issue so it was important that the weighing solution would not take up a lot of space on the production floor.”

Yamato was able to address concerns over interruptions to the Tofu King operation by installing the SDW quickly. The entire upgrade and installation progress took place over a week, with no effect on the supply to Tofu King’s customers. 

Yan said: “The new streamlined packaging process enabled by the SDW means that we can pack four times faster than before. Productivity has been increased and fewer people are required to complete the packaging process.”