Bradman Lake, a global leader in packaging technology, has successfully engineered and commissioned a customised cartoning and shrink-wrapping solution for Birds Eye, part of the Nomad Foods Group. Installed at Birds Eye’s flagship Lowestoft facility, the system is designed to efficiently package up to 770 individual potato waffles per minute into cartons in collations of 10 or 18. These cartons are then collated and wrapped in groups of 10 or 6 on edge – meeting rigorous hygiene standards and exacting customer specifications.
Project Overview & Challenges
Birds Eye required a high-speed, hygienic packaging line capable of feeding waffles into cartons, then collating and shrink-wrapping them in precise formats (10 or 6 on edge). The system needed to integrate with an extended wash-down, hand-fed infeed and allow space for downstream labelling, all while maintaining flexibility, reliability, and performance under demanding production conditions.
Bradman Lake’s Tailored Packaging Solution
Bradman Lake delivered a specialised packaging line featuring:
SL903 End-Load Cartoner
- Throughput: Up to 130 cartons per minute
- Features: Dynamic confiner for advanced control of unstable product
- Customisation: 6-metre washdown pocketed infeed conveyor tailored for Birds Eye
- Interface: Allen Bradley PanelView Plus touchscreen HMI
- Enhancements: Servo upgrade for extended infeed and fixed bucket design
- Compliance: Hygienic stainless-steel build with UKCA certification
RTSW Shrink Wrapper
- Precision: Servo-driven up-ender and collation pusher
- Sealing: Hot knife system with electronically controlled heat sealing
- Efficiency: Low power shrink tunnel with variable-speed Kevlar mesh belt
- Integration: Remote stop/start controls and labelling conveyor compatibility
- Compliance: Hygienic build with UKCA certification
Why Birds Eye Chose Bradman Lake
- Proven ability to meet stringent technical and hygiene standards
- Long-standing collaborative relationship
- Local presence for responsive support
- Outstanding after-sales service and technical assistance
Results & Impact
The installation exceeded expectations, delivering a robust, hygienic, and high-efficiency packaging line that supports Birds Eye’s high-volume production. The system is future-ready, offering flexibility for upgrades and ensuring compliance with strict food safety regulations.
“Bradman Lake’s ability to meet our exact specifications after evaluating the existing issues, design changes were designed and implemented to take this into account, they provide exceptional after-sales support which was key to this project’s success,” said Chris Wilkinson, Project Manager at Birds Eye.
“Their technical expertise and collaborative approach ensured a smooth implementation and reliable performance. From the initial design phase through to commissioning, the Bradman Lake team demonstrated a deep understanding of our operational needs and delivered a solution that not only met but exceeded our expectations. Their responsiveness, attention to detail, and commitment to quality have made them a trusted partner in our packaging operations.”
About Birds Eye
Birds Eye is one of the UK’s most iconic food brands and a cornerstone of Nomad Foods Group—Europe’s leading frozen food company. Renowned for quality, sustainability, and innovation, Birds Eye offers a wide range of frozen products including vegetables, fish, and its beloved potato waffles. The Lowestoft facility plays a vital role in delivering nutritious, convenient meals to millions of households across the UK.
About Bradman Lake
Established in 1948, Bradman Lake provides innovative packaging solutions to an international client base. The company is a leading designer and manufacturer of packing machinery and turnkey systems to the bakery & biscuit, chocolate & confectionery, dry foods, chilled and frozen foods, consumer, pharmaceutical and healthcare sectors. In 2022 the company was awarded the prestigious Queens Award for Enterprise. Bradman Lake’s manufacturing plants are located at Beccles and Bristol in the UK and Rock Hill, SC, in the United States. Bradman Lake is a wholly owned subsidiary of the multi-disciplined UK engineering and manufacturing group, Langley Holdings plc.