Adapting packaging lines to specific customer requirements is part of everyday operations at Lekkerkerker Dairy & Food Equipment. But occasionally, a project calls for a different approach. For a long-standing customer in Morocco, the solution wasn’t to adapt an existing machine but to design and build an entirely new packing system. It started with a question, moved to Peter Spruit’s drawing board, and resulted in a machine that does exactly what is needed – without unnecessary complexity.
The customer was already operating multiple lines using refurbished machines supplied by Lekkerkerker. This time, however, the requirements were more advanced. The packing line needed to handle margarine blocks in various sizes and weights, stacked in multiple layers within a box. The process had to be fast, reliable and easy to adjust. Moreover, in warmer climates it is standard practice to place a plastic liner in the box before filling, which required highly precise coordination of the full process.
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Initially, the plan was to refurbish existing equipment. But it soon became clear that this would not deliver the flexibility and reliability required. Peter Spruit, engineer and refurbishment specialist, designed a completely new machine – a semi-automatic packing system created from scratch for this specific purpose. It wasn’t a standard solution but one shaped by practical experience.
The machine packs up to 140 margarine blocks per minute. These are collected, grouped, and stacked into a complete load, which is then pushed sideways into a waiting box. The packing process is controlled via an operator panel. A recipe system allows the user to set the required format, number of rows and layers with ease.
The core of the machine is built around servo-driven linear rod cylinders. Rather than using pneumatics – which can be unstable under varying loads – or expensive full-servo systems, this design offers a reliable middle ground. It ensures stable operation while keeping refurbishment costs under control. The design focuses on durability, ease of maintenance, and maximum flexibility.
One of the key advantages of this machine is its short changeover time. Up to 90 percent of adjustments are made via software. Only essential components are adjusted manually. This keeps downtime to a minimum and efficiency high – a crucial factor in production environments where every minute counts.
Project engineer Christian Versteeg oversaw the entire process, from the first sketches to the factory acceptance test. He was involved in every step, ensuring the solution matched both technical requirements and customer expectations. The full development process took five months – an intense period of close collaboration, technical precision, and practical insight.
The new packing machine is ready for transport to Morocco, where it will be integrated into an existing production line and help improve the efficiency of margarine packaging. This project demonstrates what is possible when experience and inventiveness come together – designed in the workshop, built for real-world performance.
Do you face challenges in your dairy production, or would you like to discuss how we can support your business with the purchase, sale, refurbishment or dismantling of machines? Get in touch with us. We are happy to explore the possibilities together.