Bradman Lake delivers high-performance cartoning & shrink-wrapping system for Birds Eye potato waffles

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.

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.

Chris Wilkinson, Project Manager at Birds Eye.

This article was originally published by Bradman Lake.