Automation that benefits everyone.
How DROS was able to sustainably improve product quality, working conditions and production output simultaneously
About the company
DROS is one of the largest manufacturers of canned fruits and vegetables in Poland.
The company produces a wide range of food products in jars, including salads, juices, horseradish, gherkins, compotes, pickled mushrooms, oyster mushrooms, and numerous canned fruits and vegetables.
The product range comprises approximately 100 different products for the retail and food trade sectors.
The challenge
In 2019, DROS made one of the largest investments in the company's history.
The goal was not only to increase production output, but to make the entire production process more efficient, structured and future-proof.
Before automation, many work steps were performed manually.
Glasses had to be transported, production quantities documented by hand, and several dosing stations operated simultaneously.
This made production labor-intensive and physically demanding. At the same time, production output was limited.
Especially in the production of gherkins, precise coordination between dosing, sealing and pasteurization was crucial.
The solution
Together with Marba, a complete production line for filling and packaging pickled gherkins was developed.
The facility includes, among other things:
- Dosing system for liquids
- automatic capping machine
- Lid feed
- Conveyor technology
- ergonomically designed workplaces
- Transport technology
Later, the line was further expanded to include a dosing system for lumpy products and a capsule-setting machine.
Today, the same production line is used not only for gherkins, but also for products such as pears, beetroot, juices or barszcz.
The results
Double the production output
Daily production was increased from around 5,000 to 10,000 glasses per day – with one shift.
Fewer staff – more efficient processes
Although significantly more is produced today, the staffing requirements have been reduced from around 30 to 20 employees.
The production line automates numerous work steps, relieving employees of some of the burden in their daily work.
More structure instead of chaos
For DROS, one of the biggest advantages was not just the higher production output.
The new production line ensures clearly structured processes and sets the pace of production.
This ensures that all employees work under the same conditions and in a consistent production rhythm.
The result:
- fewer unnecessary journeys,
- less chaos,
- less physical strain,
- More efficient collaboration across the board.
As the customer describes, not only the company benefits, but above all the employees.
A regular and fair work rhythm enables higher productivity with less strain.
Higher product quality for the consumer
Automatic dosing ensures consistent fill quantities and reproducible product quality.
Overfilling or underfilling is a thing of the past.
This ensures that the consumer receives a high-quality product with consistent quality.
Because – as the customer himself says:
"Everything we do, we do for the consumer." - Joanna, Managing Director of DROS
The collaboration
DROS has been working with Marba Sp. z oo since the 1990s.
Over the years, several projects have been successfully implemented and continuously expanded.
Particularly appreciated are:
- many years of experience in the food industry,
- deep process understanding,
- practical solutions,
- Individual adaptation to the customer's production.
Conclusion
With the new production line, DROS was able to:
✔ double daily production
✔ reduce staffing needs
✔ improve product quality
✔ to sustainably optimize work organization
✔ Create better working conditions for employees
✔ Make production more efficient in the long term.
💡 Expert tip from Machines4FoodIndustry
Why does a well-planned production line improve not only productivity but also working conditions?
Automation does not mean replacing people.
An intelligently planned production line reduces unnecessary manual work steps, creates clearly structured processes and ensures a consistent production rhythm.
This not only increases production efficiency, but also reduces physical strain, makes work processes more transparent, and ensures more consistent product quality.
The best automation projects therefore create added value for all involved – for the company, the employees and the consumer.
Paweł Grabiec
Managing Director Marba Sp. z o.o.
Engineering partner of Machines4FoodIndustry
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