Push the Limits With 67% Less: Maximize Results While Minimizing Emissions

In a time marked by a focus on innovation, precision, reliability, automation, and sustainability within the food industry, a partnership between two industry leaders has led to a revelation: Faerch’s patented Ultra Low Stacking trays. Achieving up to 67% space savings during transport, storage, and handling, whilst achieving a tray denesting success rate of 99.96%, these trays deliver exceptional results.

Unlocking 67% Space Savings

At the heart of the Ultra Low Stacking tray’s innovation lies the noteworthy 1.5 mm gap between each tray, a significant contrast to the 3-6 mm gap found in traditional trays. An intricate stacking configuration that required an adaptable and precise tray denesting solution. A challenge that could only be solved through close collaboration between tray manufacturer and tray denesting manufacturer.

Considering the impressive tray denesting success rate of 99.96%, it’s worth noting that even the rarest denesting errors are automatically rectified by the INTRAY Buffer Servo’s smart auto-correct feature. This ensures impeccable production uptime with no production stops, showcasing the system’s remarkable reliability.

A Sustainable Paradigm Shift

The Ultra Low Stacking trays did not only meet Norfersk’s need for a tray that matched an adaptable production while being made from recycled material, but it was also proof that innovation and sustainability are intertwined ideals – something the Ultra Low Stacking trays both deliver on.

Highlighting up to 67% space savings during transport, transit packaging, storage, and handling, these trays translate to significantly reduced CO2 emissions — a testament to Faerch and QUPAQ’s commitment to crafting solutions that excel across multiple dimensions. Simply: less is more.

The Future of Packaging

In essence, Faerch and QUPAQ developed a match between the trays and the tray denester, resulting in resounding success at Norfersk. With more than 38 million trays denested at Norfersk, the Ultra Low Stacking trays serve as a proof that innovation flourishes in environments where complementary competencies come together to produce results greater than the sum of their parts. Rasmus Haage Sørensen’s statement encapsulates this achievement:

“Now the big question is whether the investment can pay off, and the answer is simple: yes, it can. The amount of money invested in this project pales in comparison to the returns we’ve seen.”

In summary, this collaboration did not only redefine what’s achievable in terms of functionality, but it also showcased the importance of the dance of millimeters that contributes to a brighter, more efficient, and sustainable future within the packaging solution.

After more than three years in production, Norfersk highlights the following achievements resulting from the synergy of Faerch’s Ultra Low Stacking trays and QUPAQ’s INTRAY Buffer Servo:

• A 99.96% denesting success rate, resounding in exceptional uptime.

• Approximately a 67% reduction in transport, handling, and storage requirements, resulting in significantly lower CO2 emissions.

• A substantial reduction in maintenance costs has been saved compared to the years before.

• Smooth transitions between trays with different heights with no need to switch tools.

• More than 38 million trays denested since the implementation.

Faerch is a leading supplier of circular, rigid food packaging and with integrated recycling capability. We serve food manufacturers and retailers around the world with our network of state-of-the-art production facilities across Europe.

Faerch supply food manufacturers, food retailers, food service providers, and airlines with food packaging solutions designed to optimize their production flow, supply chain and total cost of ownership.

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