Layton Systems' Stainless Steel Box Crusher is designed to break up frozen product inside cardboard boxes before further processing.
Layton Systems
Does anybody really enjoy dropping things? Maybe a rollercoaster or some other sort of amusement park ride would be among the exceptions, but how about something sliding through your grasp to hit the floor? Something might break, something could spill, and nobody likes dropping something on their toes. Now imagine going to work and having to drop boxes of frozen raw ingredients onto the floor to separate them and then restack the boxes. Such was the case for employees at Homestyle Direct where a pallet of two hundred cases of sweet potatoes took three team members three hours to break up by hand. But that process is a thing of the past thanks to the Stainless Steel Box Crusher.
The Stainless Steel Box Crusher comes in two models, one with a powered feed and exit, and another that's unpowered.Layton SystemsHomestyle Direct is a leading provider of nutritious and convenient meal services. Headquartered in Twin Falls, Idaho, the company specializes in offering healthy meal choices to people all across the U.S., including Medicaid and Medicare Advantage members in need of home-delivered meals. The company is especially focused on health and well-being, which made it stand out that there was this labor-intensive process to break up frozen ingredients by hand going on in its own facility.
A team member from HSD decided to fix that after watching employees perform the cringeworthy task that invited injury—not to mention the food safety element of tossing ingredients to the floor. An internet search turned up Salem, Ore.-based Layton Systems, which offers a number of quality food processing equipment solutions for a variety of industries. In this case, a YouTube video showed the capabilities of the Stainless Steel Box Crusher.
“I had no problem learning how to use the machine. Not only is it faster to crush and open boxes, we have an easier time mixing the product. Before the box crusher, manually crushing and opening the boxes caused a lot of strain on our backs and shoulders.” — Marissa, Head Cook, HSD
The right find
The video showed a machine designed to break up frozen product inside cardboard boxes before further processing. The process is straightforward: A sealed cardboard box with frozen crystallized product inside is placed on the Box Crusher’s conveyor infeed. The infeed opening is adjustable to crush boxes 9-in. to 14-in. wide with a maximum height of 14 in. Once inside, four crush rollers with a tensioner located inside the machine pull the boxes through the machine while pressing them to break the product apart into individual pieces. The box exits on the other side when the process is complete.
The machine has proven to be a valuable time saver to break up frozen vegetables at Homestyle Direct.Layton SystemsTwo models are available, one with a powered conveyor feed and exit, and the other unpowered. It features a T-304 stainless steel construction with nickel-plated drive components. Overall dimensions of the both models are approximately 74-in. wide x 119-in. long x 67-in. high and powered by a 1.5 hp drive gear motor.
Dawson Mosey, Western Sales & Marketing Manager for Layton Systems tells ProFood World that HSD purchased the first unit as a beta test and after only a short timeline ordered a second unit for its other location. It’s his understanding after communicating with HSD’s Twin Falls location that the unit works better than anticipated and the operators love it.
“It has a been a wonderful change to my job as opening team leader. I don’t need as many people to get the job done, and it’s much less exhausting compared to the prior process. The box crusher is also easy to operate, and achieves a much higher volume of production while decreasing our physical workload.” — Rubi, Opening Team Lead,HSD
While the Box Crusher improves the speed with which HSD is able to process frozen ingredients, it’s the safety and comfort of employees that has really stood out. “The Box Crusher also provides our employees with a safer, more ergonomic way of handling these materials,” says John Hahn, Production Manager for Homestyle Direct. “Manually lifting and breaking the materials required significant effort; now with the assistance of lift pallet jacks, we slide the boxes into place and it’s done. Further, the controls are easy to follow, requiring minimal training, and the integrated safety controls provide peace of mind while operating. Finally, the teams working with the box crusher have mentioned how easy it is to clean, with large side doors opening to the inside, allowing ample room to clean thoroughly.”
“The Box Crusher from Layton systems has proven to be a significant asset for Homestyle Direct (HSD),” says Hahn, “providing a more efficient and ergonomic way of handling our raw ingredients.”
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The Stainless Steel Box Crusher comes in two models, one with a powered feed and exit, and another that's unpowered.Layton Systems
