When a packaging line stalls, so does the entire production chain. At Tanganda Tea Company, one of Zimbabwe’s leading tea producers, a critical Vertical Form Fill Seal (VFFS) machine had suffered progressive wear across its pneumatic, mechanical, and electrical systems, threatening operational efficiency.
That’s where Hoodridge Industrial Automation came in — to carry out a complete machine overhaul, restoring the unit to peak performance.
Project Overview: From Breakdown to Full Rebuild
This wasn’t a routine service. The scope included a full teardown and rebuild of the VFFS machine, involving:
- Pneumatics: Replacing air cylinders, solenoid valves, flow restrictors, and tubing
- Mechanical: Fabricating and replacing worn cam assemblies, belt systems, shaft bushings, film feed mechanisms and drive rollers
- Electrical & Controls: Rewiring the panel, replacing faulty relays, sensors, limit switches, and integrating a new HMI interface
- Sealing System: Calibrating heaters and replacing temperature control units for vertical and horizontal sealing jaws
- Safety Upgrades: Adding emergency stops and enclosure interlocks to improve operator safety
We also conducted dry-run and full-product testing, ensuring the rebuilt machine could operate reliably at production speed.
About VFFS Machines
VFFS machines are at the core of modern tea ad food packaging operations. They:
- Form pouches from roll film
- Fill them with measured amounts of tea
- Seal them — vertically and horizontally — at high speed
This integrated process relies heavily on precise timing, airtight sealing, and clean mechanical motion.
Project Outcome
After the rebuild, Tanganda experienced:
- Restored production capacity and throughput
- Improved packaging consistency and seal integrity
- Longer machine life and easier maintenance access
The upgraded system now meets modern performance and safety expectations — a transformation from a fatigued asset to a reliable production workhorse.
Need to bring your packaging equipment back to life?
From tea lines to snack automation, Hoodridge offers full mechanical, electrical, and pneumatic rebuilds.
