Færch A/S reports growth at new UK manufacturing facility

On-going investment in key initiatives helps boost production of plastic trays & containers for ready meals, meat & poultry and cold foods and snacks.
Færch A/S – one of Europe’s leading producers of plastic containers for the food industry – is delighted to report significant growth at its UK manufacturing facility since the official opening in June 2012.
The company attributes this success to on-going investment in state-of-the-art production equipment, high calibre workforce and in-house design and innovation, as well as hygiene, quality and environmental standards.
Firmly on track to meet its annual output target for CPET ready meal trays, Faerch’s Durham site has also started to manufacture containers from high clarity APET and PP materials for cold foods and snacks, including bakery, dairy, fruit, vegetables and cold meats.
The purpose-built, 14,000m² plant, which is Faerch Plast’s first in the UK, has already grown its number of thermoforming machines from eight to 18 with another three due to be commissioned by the end of 2013. Several cutting-edge robot packing lines have also been installed.
Talking about the amount of progress the facility has made against initial forecasts, Joe Iannidinardo, MD of Faerch’s UK operation says: “Our original objective was to install 15 thermoformers so the fact we are now up to 18 is impressive by anyone’s standards.”
“There will eventually be around six robot packing lines which will help to keep man hours low and further boost production output. Robot packing is becoming common in our sites in Denmark, Czech Republic as well as the UK."
“In fact, despite not being commonplace in the packaging industry in general, we are utilising these bespoke robotic solutions more and more across all three plants.”
As well as enhancements to its production area, Faerch has completely refurbished the reception, leisure and office spaces.
The workforce has already grown from 36 to 60, but eventually the plant will provide 100-150 permanent jobs. Færch A/S employs some 500 across all three of its factories.
In line with its environmental objectives, Faerch has been successful in offering a closed loop - Cradle to Cradle - process for the manufacture of trays from post-consumer recycled PET, or rPET. 

Food grade rPET flakes are purchased from two of the UK’s top plastics recycling companies. Further cleaning and careful control of the extrusion and thermoforming process at Durham ensures maximum recycled content.

For a completely closed loop, Faerch has been heavily involved in a project aimed at making black trays more recyclable. CPET ID is a revolutionary new packaging material which will allow trays produced from black CPET to be sorted in the mixed plastics waste stream, for the first time ever.
Joe adds: “The new plant has definitely given Faerch major competitive edge. Our UK customers have been keen to visit the plant and it is obvious that they are reassured by the benefits offered by local supply, including closer support and enhanced lead times.”
“The senior management team is confident that the factory will continue to go from strength to strength, with further significant growth ensuring we soon reach our target of filling the available capacity.”
“The future certainly looks bright for Faerch in the UK,” concludes Joe.
Færch A/S has also acquired a plot adjacent to the factory, and as a consequence now has 30,000 square metres of industrial site at its disposal in Durham. This will allow for the possibility of further expansion as demand increases.