Develop new fully automated grow with demand vacuum packing system

This project was undertaken to solve two critical problems for red meat processors: the lack of floor space in already crowded boning rooms, and the high cost of upgrading or replacing packaging equipment when demand increases. Traditional rotary vacuum systems occupy a large footprint, making them difficult to install in most facilities, and require major investment when capacity needs change. The solution developed was a patented “Grow with Demand” vacuum packaging machine that requires very little floor space and can expand capacity as needed.

The project was carried out in four stages: design and engineering, prototype build, long-term testing, and industry validation. Advanced computer modelling guided the chamber design, which was then refined through hands-on testing. Close collaboration with processors ensured the machine was designed around real-world constraints and industry-preferred components were adopted to support reliability and acceptance.

The key results were the successful development of a prototype with a footprint of only 5 m² —significantly less than rotary systems —while achieving speeds of up to 50 packs per minute and reducing energy use by up to 50%. The modular design allows smaller processors to start with a single-chamber machine and later add a second chamber to double capacity without any extra floor space. For larger processors, the double-chamber system is a direct replacement for rotary machines, offering higher efficiency and much lower space requirements.