Fairfields Farm is a family-owned premium crisps manufacturer based in the UK. Run by third-generation farmers, the business grows its own potatoes and hand-cooks its crisps on-site – offering a genuine field-to-farm-gate story that sets it apart.
A focus on supplying independent retailers across the country helped the brand stand out in a competitive market, supporting consistent growth.
Fairfields Farm is also committed to sustainability through initiatives such as biocrop production, reservoir management, and tree planting. The business is well on its way to achieving carbon neutrality and aims to reach net-zero emissions by 2030.
Its commitment to quality – both in potato selection and production methods – has played a key role in driving continued success. This growth positioned the business to invest in a fully integrated snack food packing system from Ishida, designed to meet increasing production demands.
“Quality is central to every stage of our production – from the potatoes we select to the machines we use,” said the company’s operations director Simon Heard.
With over 30 years’ experience in food production, Heard was already familiar with Ishida’s reputation for high-quality equipment.
“When it came to selecting a supplier, they were a clear choice,” he said.
But it wasn’t just the machinery that stood out – exceptional aftercare also played a key role. When the company urgently needed a replacement belt, it was delivered on the same day.
With trust in Ishida established, the next challenge was finding a system that would deliver results within the farm’s limited floorspace. He said the compact footprint of the Ishida line was a key benefit.
Ishida delivered a space-efficient solution that ticked all the boxes. The new automated packaging line now runs alongside the existing line, which handles larger pack sizes with lower speed requirements. The system includes an RV series 14-head multihead weigher, INSPIRA bagmaker, seal tester, checkweigher, and ACP-711 Automatic Case Packer.
Since installation, Fairfields Farm has increased output, achieved better quality control, and deployed staff more efficiently. The multihead weigher and bagmaker combination handles pack sizes from 25g to 150g at up to 120 packs per minute – delivering a 50 per cent increase in speed. The weigher offers accuracy within 4 per cent of optimum target weight, significantly reducing product giveaway, especially on the popular 40g size. This is a notable achievement, given an individual crisp can weigh as much as 1.3g.
The Ishida Case Packer has kept pace with the rest of the line, enabling the re-deployment of 2–3 workers to an extra shift.
“With manual case packing, we needed 2–3 people at the end of the line. The Ishida ACP Case Packer freed them up, making it easier to add an extra shift,” said Heard.
Quick changeovers were another key advantage. The CCW-RV-214’s hoppers are easy to remove for fast cleaning during flavour changes, while the case packer can switch between formats at the touch of a button. The Ishida Seal Tester and Checkweigher enhance quality assurance, rejecting out-of-spec packs and ensuring optimal air-fill during packing. The seal tester also sends air-fill data to the bagmaker, allowing automatic adjustments for consistent pack thickness and smooth case packing.
“The INSPIRA screen is clear, helping staff quickly identify and resolve any issues,” said Heard. “It also supports multiple languages, enabling rapid training of a diverse range of staff.”
Ishida’s fully integrated snack food packaging system is not only supporting current production needs, but also forms a key part of their five-year expansion plan — with a return on investment expected within just two and a half years.
Facts and Figures:
- Speed Increase: The new installation handles bag sizes from 25g to 150g at speeds up to 120 packs per minute, which is a 50 per cent increase.
- Labour Efficiency: The installation of the Ishida Case Packer facilitated re-deployment of 2-3 people for an extra shift to meet increased demand.
- Flexibility: The case packer can be quickly switched between case formats at the touch of a button.