Client: Carley鈥檚
Industry: Organic Food Manufacturing
Established Relationship: 20+ years
From Domestic Kitchen to Full-Scale Production
What began as a small family venture supplying wholefoods has evolved into a thriving organic manufacturing operation. Thanks to Adelphi machinery, Carley鈥檚 has increased productivity tenfold, enabling the transition from domestic-scale production to a fully operational 1/3 acre bespoke manufacturing site (shaped like an almond!).
The Challenge
To support a growing product range and customer demand, Carley鈥檚 needed to move from manual filling and capping to scalable, efficient production - without compromising their values or product quality.
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Originally:
- 3 staff
- 3 products
- Manual filling and capping
Growth quickly made this model unsustainable.
The Solution
After meeting Adelphi Manufacturing at a speciality food exhibition in 2006, Carley鈥檚 implemented the Response Benchtop Filler to support their expanding production.
Intuitive & Flexible Operation
- Handles all viscosities across nut butters, chutneys, relishes and more
- 3-minute strip-down for cleaning
- Fast container and product changeovers
- Simple, intuitive operation
- In-house servicing by trained staff
Rachel Sutton explains: 鈥淲e could have outsourced some of our processes, but that really isn鈥檛 us. We like to do everything ourselves, in-house 鈥� it fits with our values.鈥�
Production Manager Cathy adds: 鈥淲e鈥檝e got the changeover between different containers and products down to a fine art!鈥�
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The Results
- Portfolio expanded from 3 products to 50+ nut and seed butters (with more in development)
- Capacity to process up to 4,000 jars per day
- Over 200 cases filled in under 2 hours during peak periods
- Team busier than ever
Rachel reflects: 鈥淲e had smaller batches and a smaller range 鈥� around 1/10 of what can be achieved now.鈥�
Automating Filling AND Capping
As the long-standing relationship developed, Adelphi offered Carley鈥檚 the opportunity to trial the innovative Response Monobloc filling and capping machine.
Protecting Previous Investment
Carley鈥檚 existing Response Benchtop Filler fits inside the Monobloc 鈥� meaning production can be scaled up without making earlier investment obsolete.
Solving Leakage & Waste
Manual capping had been causing inconsistent torque, leading to oil leakage during transit 鈥� creating financial risk and reputational damage.
鈥淲e risked credit claims from one of our biggest private label customers鈥� Only the good relationship between us prevented this.鈥�
The Impact of Vacuum Capping
- Dramatic reduction in leakage complaints
- Wastage reduced from 30% expected loss (manual capping) to <0.07% using the Monobloc
Rachel confirms: 鈥淭he vacuum application is working brilliantly, and there have been dramatically fewer 鈥� I can鈥檛 really think of any 鈥� complaints about leakages.鈥�
- Improved Staff Safety & Comfort
Manual capping had also led to repetitive strain injury (RSI) concerns.
The Monobloc鈥檚 vacuum capping system has:
- Eliminated RSI issues
- Improved staff comfort and morale
Carley鈥檚 supports a positive work-life balance with a four-day working week 鈥� and plenty of encouragement from their dogs, Badger, Jasper and Robin.
Complete In-Person & Remote Support
Adelphi鈥檚 Design Engineer, Anand, provided hands-on and remote support via PLC connection for fast diagnostics and troubleshooting. During commissioning, Anand identified inconsistencies in Carley鈥檚 jar caps 鈥� prompting a supplier change and further reducing waste costs.
Shared Values 鈥� Sustainable Manufacturing
Carley鈥檚 and Adelphi share a strong environmental ethos, including:
- PV solar panel energy generation
- Rainwater harvesting
- Proactive recycling culture
Both businesses demonstrate that manufacturing can be carried out responsibly and sustainably.
Key Outcomes
- Tenfold productivity increase
- Up to 4,000 jars per day
- 30% 鈫� <0.07% wastage reduction
- Expanded 50+ product portfolio
- Improved staff safety
- Sustainable, in-house production growth
Adelphi are proud to have supported Carley鈥檚 throughout this remarkable journey 鈥� and look forward to continuing a very special partnership for years to come.
