Do It Like a Pro!

WG Pro-Manufacturing Inc. has carved itself a tidy little niche in the Canadian consumer goods industry since its inception in 1993 by company president Karl Wirtz.

Starting out in a modest 9,000-square-foot facility, the company initially focused on managing reclaimed and returned products for a major pharmaceutical company. Over the years, WG Pro has transformed into a major repacking services provider with expansive facilities in the greater Toronto area and Lethbridge, Alta.

Today, WG Pro is a growing powerhouse in the co-packing industry, offering a comprehensive range of services including ambient, frozen, and refrigerated product packaging.

By consistently evolving and embracing innovation, WG Pro has built a reputation for excellence and reliability, serving high-profile clients like PepsiCo, Laura Secord, Nestlé and Kellogg’s.

As Wirtz recalls the company’s earlier days, “It’s amusing to think that when I started the business, I wasn’t even familiar with the term ‘co-packing’.

“At the time, I was running an employment agency, hiring and placing packagers in other companies’ facilities. It dawned on me that this presented a unique opportunity to offer our clients a more streamlined service,” he relates.

“By providing a controlled environment where we could handle the packaging for them, we helped alleviate congestion in their spaces.

“Thus, I ventured into the co-packing industry almost inadvertently.”

Today, WG Pro offers a comprehensive range of services designed to meet diverse client needs. One of their key services is managing the co-packing process for ambient, frozen, and refrigerated products with unmatched skill and expertise.

As Wirtz explains, “Our clientele primarily consists of multinational companies that produce traditional foods and rely heavily on automation.

“We operate at high speeds, running a single SKU (stock-keeping unit) with minimal human intervention to efficiently package products.

Also known for its expertise in assembling innovative private-label food kits, WG Pro collaborates with retailers and food manufacturers to create unique offerings—such as the marshmallow S’mores Kits and Gingerbread Kits—as well as exploring innovative combinations of sweet and savory snack-foods.

“We provide products to retailers for private label sales, including companies like Walmart, President’s Choice and Loblaws,” Wirtz notes. “We help our clients innovate and bring new products to market, working closely with them to create unique packaging solutions.”

WG Pro’s facilities boast a dedicated 6,000-square-foot area for cold and frozen repackaging, equipped to handle various tasks such as multi-packs, carton-filling, pouch-filling, over-relabeling, and display building.

The company also offers rework services to rectify unexpected errors, supported by a team of experts available for consultation and project assistance involving labels, displays and packaging.

“Our expertise in handling multi-pack products has become our hallmark,” states Wirtz. “We provide innovative packaging solutions that combine multiple flavours and different types of products in a single box, catering to the needs of retail giants like Costco and Walmart.”

WG Pro upholds stringent quality and safety standards, as demonstrated by its BRC A rating under the Global Food Safety Initiative (GFSI) program. Additionally, the facility features a dedicated nut-free area to ensure safety for clients with specific allergen requirements.

The integration of cutting-edge robotics and automation has significantly reduced labour costs at the company in recent years, while enhancing production efficiency.

Currently, WG Pro employs approximately 180 people across two facilities, including a 102,000-square-foot facility in Brampton and another 80,000-square-foot building in Lethbridge.

Both facilities are fully equipped for refrigerated storage, capable of handling milk products, dairy products, cheese, pizza, ice cream and a wide array of other refrigerated items.

Like many other companies, WG Pro hit a rough patch during the second year of the COVID-19 pandemic a couple of years ago, as it was unable to find enough workers to keep the operation going.

“Faced with the challenge of finding workers, I turned to my longtime friend Mark Evangelista, director of sales at PLAN IT Packaging Systems, and decided it was time to automate our plant.”

Based in Mississauga, Ont., PLAN IT Packaging Systems specializes in providing custom-tailored automated packaging solutions for customers across a broad range of CPG (consumer-packaged goods) industries including food and beverage, baked goods, confectionery, frozen foods, pet care, household goods, personal care, and beauty and cosmetics, among others.

With ready access to a comprehensive assortment of high-performance packaging equipment covering all aspects of packaging line operations: the company is guided by a clear and resolute mission: to engineer robust, turnkey automated packaging solutions that not only optimize efficiency and bolster productivity, but also foster sustainable growth for their clientele.

To achieve these goals, PLAN IT partners with its customers allows a seamless journey of on-site consultations, meticulously crafted development strategies, precise system installations, bespoke training programs, and continuous equipment maintenance and support.

As Wirtz recalls, “I knew Mark from his previous career posting, and so when he started at PLAN IT Packaging Systems, he was eager to show me his new operation and machinery.

“I was particularly impressed by the portable bagger he introduced me to,” Wirtz says. “As a custom packager, we needed the flexibility to move equipment throughout our facility, including into our nut-free room when necessary.

“We also needed to be able to sanitize and reposition it as needed,” he adds. “The portability of the PLAN IT Packaging Systems bagger was perfect for our needs, and I absolutely loved it!”

PLAN IT Packaging Systems provides clients with a comprehensive array of advanced machines designed to automate the packaging processes effectively, thereby enhancing efficiency and productivity.

Integrated with automated weighing systems, these solutions ensure precise measurement and compliance with weight regulations—crucial for maintaining consistency in packaging weights, reducing giveaway, and minimizing product waste.

In addition to automated weighing, PLAN IT Packaging Systems also furnishes clients with a range of automated packaging equipment, automated filling machines, sealing equipment and labeling systems.

These machines streamline the packaging process, ensuring consistent packaging quality while reducing manual labour requirements. They are adaptable to various packaging formats and materials, optimizing throughput and operational efficiency.

Integrated conveyor systems play a pivotal role in PLAN IT Packaging Systems’ automation solutions for its clients, facilitating smooth product flow between different packaging stages.

These systems are customizable to fit specific production layouts and can incorporate features like accumulation zones, diverter gates, and automatic sorting mechanisms, which maximize throughput and minimize downtime.

For handling finished products, PLAN IT Packaging Systems offers client high-performance robotics and palletizing systems. These robotic solutions automate the stacking and palletizing process—thereby increasing efficiency, reducing labour costs, and enhancing workplace safety by handling heavy loads and repetitive tasks effectively.

To ensure product quality and safety throughout the packaging process, PLAN IT Packaging Systems integrates quality control and inspection systems with special capabilities that include advanced vision inspection systems and metal detectors that detect defects, contaminants, and ensure packaging integrity, thus minimizing the risk of product recalls and bolstering consumer trust.

Wirtz fondly remembers the first piece of equipment he purchased from PLAN IT Packaging Systems—the Mars ComPak vertical form/fill/seal (VFFS) bagging machine.

“We opted for the Mars ComPak due to its exceptional flexibility,” Wirtz says.

“Previously, we handled this process manually, receiving bags from various companies that required filling, weighing, sealing, date-coding, and presentation.

“The Mars ComPak allows us to achieve a production rate of approximately 40 bags per minute,” says Wirtz. “To match this output manually, we would need around 24-to-25 personnel.

“With this machine, we can manufacture the product, organize it by flavor, and efficiently process it using our automated secondary packaging machinery,” he remarks.

“This set-up allows us to handle each flavor separately, from production to packaging.

“Remarkably, we are considering purchasing five additional units,” says Wirtz, complimenting the PLAN IT technicians on the quick and seamless system installation and commissioning.

“The system implementation was flawless,” Wirtz states. “It arrived promptly, and their technical team set it up without a hitch.

“They ensured smooth operation and conducted thorough training for our team and staff, which was excellent,” he adds. “The bagger’s multiple forming tubes immediately provided us with enhanced flexibility.”

Says Wirtz: “The Mars ComPak is an advanced multi-head weighing and packaging system designed to handle high-speed, precise packaging operations—making it ideal for a diverse range of products, including confectionery items and pet food.”

Equipped with 14 individual weighing heads, each capable of weighing small portions of the product with high accuracy, the machine ensures that the combined weights meet the target weight for each package precisely.

Despite its advanced capabilities, the machine’s compact design allows it to fit seamlessly into existing production lines without requiring significant modifications.

According to PLAN IT, the Mars ComPak machine can handle different product sizes and shapes, allowing for quick changeovers between different products.

The machine includes an intuitive touch-screen control panel that simplifies operation, allowing operators to easily set up and adjust the machine for different packaging tasks, enhancing operational flexibility.

Integrated quality control systems ensure that every package meets stringent quality standards, including accurate weighing, consistent sealing, and proper labeling of each product.

Additionally, the machine is designed to minimize material waste and reduce the environmental impact of packaging operations.

In addition to confectionery products, the Mars ComPak is also widely used to package other dry food items such as rice and ready-to-eat meals, under brands like Ben’s Original and Dolmio.

The benefits of the Mars ComPak machine include increased accuracy, efficiency, cost-effectiveness and quality control. By reducing product giveaway and ensuring consistent package weights, the machine maintains product quality and reduces costs.

Its high-speed operation optimizes operational efficiency, while quick changeover capabilities enhance flexibility—allowing the machine to switch between different products and packaging formats with minimal downtime. This precision and versatility helps users maintain high standards of product consistency and quality.

In the packaging process, the product is fed into the top of the weigher, typically via a vibrating feeder or conveyor.

The product is then distributed across the 14 heads, with each head weighing a portion of the product.

The machine calculates the best combination of weights from the 14 heads to achieve the target weight and releases the selected combination into the packaging machine, where it is packed into bags or pouches.

As Rick Neill, senior technician from PLAN IT Packaging Systems, explains: “The Mars ComPak functions as a two-in-one unit featuring a built-in scale. The process starts with product counting at the top, followed by the product dropping through our funneling system into the bagging area.

“The bags are then sealed, cut and discharged via the conveyor,” Neill states, while singling out the machine’s user-friendly HMI (human-machine interface) panel controlling both the bagger and the scale.

“This interface allows us to adjust parameters such as bag length, speed and jaw settings,” Neill notes.

“Another impressive aspect is its dual-station capability,” he continues. “The HMI manages both the weighing and packaging stations, configurable for weight or counting through its parameters.

“Our primary screen includes a comprehensive run button, activating the product release from the top weigh buckets.

“Inside the machine, we have a forming tube, pull belts, and a bag deflator to manage excess air, ensuring a flat package,” Neill states.

As Wirtz explains, the Mars ComPak machine has already proved to be a good fit for the WG Pro’s highly automated secondary packaging line installed and integrated by the Toronto-based engineering-services firm Cyntek Industrial.

The tightly synchronized secondary packaging system comprises one AFA cartoner (manufactured by Brampton, Ont.-based AFA Systems Ltd.), one AFA case former, one AFA dual case/carton closer, one AFA central conveyor, and six ABB FlexPicker “pick-and-place” delta robots.

In operation, the AFA machines take flat, unfolded cartons and assemble them into their final shape, ready to be filled with product.

Once the cartons are ready, the ABB FlexPicker robots take over, using their advanced vision system to locate, pick up and load the conveyed items or primary packages inside the formed cartons with utmost precision at very high line speeds.

“Each robot meticulously counts and loads its assigned products into the boxes, “Wirtz states. “The entire process is controlled by microprocessors.”

As Wirtz notes, the system is designed to ensure seamless integration and coordination between the various components. This involves synchronized control systems that manage the timing and operation of each machine, ensuring that the sachets are picked and placed into cartons smoothly and efficiently.

The integration also includes safety mechanisms and error-checking processes to handle any discrepancies or issues that arise during operation, maintaining the quality and reliability of the packaging process.

“The automation is seamless: carton erection occurs on the left, followed by the boxes moving through the line where they are filled, counted, and proceed to the end for ejection, weight check, sealing and date coding,” Wirtz relates.

“This line has reduced the need to have 20 people per shift,” says Wirtz, adding he’s looking forward to further efficiency gains with the arrival of more PLAN IT bagging systems in the future.

“PLAN IT Packaging Systems’ baggers will play a crucial role here, with each feeder having a bagger feeding into it—subsequently integrating the product into the line,” he says.

“This system can handle both corrugated and carton boxes with ease,” says Wirtz, adding this flexibility will be vital to support the company’s ambitious growth plans.

“We are currently exploring the establishment of a new facility in Tennessee or Georgia,” he relates, “while a major Canadian customer is looking to partner with us in an exciting initiative we’ve been aspiring to undertake for many years.

“There is no doubt that our advancements in automation are creating new opportunities for us to realize these goals.”