Europe Tortilla Production Line

Tortilla Production line in Europe

Location

London，UK

Equipment

PXTA-740 Tortilla Production Line

Application

Tortilla / Wrap Production

Project Type

Production Line Upgrade

Main Goal

4000psc/h

Project Overview

The customer is a UK-based food processing company producing tortillas, wraps, and related flatbread products. Before working with PROX, the customer used a semi-automatic production line with high manual involvement. As product demand and quality expectations continued to grow, the customer needed a more stable and efficient automated solution.

Customer Challenges

High Labor Dependency

The previous semi-automatic line required frequent manual operation, increasing labor costs and making production efficiency dependent on operator experience.

Limited Production Capacity

As customer orders increased, the existing production setup could no longer meet the demand for higher and more stable output.

Inconsistent Product Quality

Manual handling affected tortilla size, thickness, baking quality, and appearance consistency.

Factory Layout Limitations

The customer needed a production line that could fit the existing factory layout while supporting future expansion.

PROX Customized Solution

After understanding the customer’s production challenges, PROX optimized the solution around product consistency, target capacity, labor reduction, and factory layout. The final PXTA-740 Tortilla Production Line helped the customer upgrade from semi-automatic production to a more stable and efficient automated process.

1. Quality Control Improvement Optimized key processes including dough forming, hot pressing, baking, and cooling to improve tortilla size, thickness, and baking consistency.

2. Capacity-Matched Line Configuration Recommended the PXTA-740 line based on the customer’s product size, output target, and future order growth.

3. Reduced Manual Handling Connected dividing, rounding, proofing, pressing, baking, cooling, counting, and stacking into a continuous production flow.

4. Layout Adapted to Existing Factory Planned the line according to the customer’s available space and production flow, reducing the need for major factory changes.

5. Smooth Upgrade from Semi-Automatic Production Focused on practical operation, commissioning, and training to help the customer adapt quickly to the automated line.

Equipment Configuration

Equipment List

1 Chunker
2 Elevator
3 Divider Rounder
5 Dough Ball Distributor Table
6 Press (740*740)
7 Oven
9 Cooler Conveyor
10 Counter Stacker

Installation & Commissioning

After the equipment arrived at the customer’s factory, PROX arranged on-site installation and commissioning support. Before the engineer’s arrival, we provided the customer with layout drawings, electrical connection points, voltage and power requirements, and gas requirements for the oven, helping them prepare the site in advance. The whole installation and commissioning process took about 10 days.

1

Engineer Arrangement

After receiving the customer’s installation request, PROX arranged the engineer’s visa application and confirmed the service schedule after the visa was approved.
2

Site Preparation Support

Before departure, we provided the production line layout, equipment positioning plan, electrical connection details, and gas requirements, helping the customer prepare the site in advance.
3

Installation & Line Connection

In the first 3–4 days on site, the engineer completed equipment positioning, module connection, electrical wiring, air/gas connection, and partial equipment assembly.
4

Commissioning & Training

After installation, the engineer carried out line commissioning, trial production, parameter adjustment, and operator training, including equipment operation, adjustment, maintenance, and safety guidance.

Project Results

Compared with the previous semi-automatic line, which produced about 2,000 pcs/h for 8-inch tortillas, the new PXTA-740 line can reach around 7,000 pcs/h for 8-inch tortillas, greatly improving the customer’s ability to handle growing orders.

Improved Production Capacity

Tortilla size, thickness, appearance, and baking quality became more uniform, helping the customer deliver more stable product quality to the market.

Better Product Consistency

The previous production line required 5–6 operators, while the new automated line reduced the required labor to around 3 operators, lowering labor dependency and improving production efficiency.

Reduced Manual Handling

Project Value Summary

This project shows how food manufacturers can upgrade from semi-automatic production to a more efficient automated tortilla production system. For factories facing rising labor costs, increasing orders, unstable product quality, or limited production space, PXTA-740 provides a practical and scalable solution.

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