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Pea Freezing Operations
Part 2. Packaging and Freezing
G. B. Davis
H. M. Hutchings
N3—R441
'
1
APR 25 1960
\Oft,
Miscellaneous Paper 87
March 1960
Agricultural Experiment Station, Oregon State College, Corvallis
in cooperation with
Agricultural Marketing Service, United States Department of Agriculture
This report is the second•in a series dealing with costs and
efficiencies in pea-freezing plant operations. The first dealt
with vining and has been published by the Oregon Agricultural
Experiment Station as Miscellaneous Paper 66, January 1959.
These studies are being made under a regional research project concerned with the marketing of frozen fruits and vegetables.
The Experiment Stations of Oregon, Washington, California, Hawaii,
and the Agricultural Marketing Service, U. S. Department of Agriculture are cooperating in this program.
Authors: G. B. Davis is Agricultural Economist
H. M. Hutchings is Junior Agricultural Economist
INTRODUCTION
The Pacific Northwest produces and processes over 60 percent of
the nation's frozen peas. This region is able to supply the market with
such a large proportion of its needs because it has been able to compete
effectively with other regions on the basis of cost and quality of product. Increasing labor, transportation, and supply costs in the Northwest
relative to other producing areas, however, make it necessary for both
producing and processing segments of this industry to be aware of ways to
improve efficiency and reduce costs. This must be done if the Northwest
is to continue as a major supplier of frozen peas.
This report has been prepared in hope that information presented
will guide freezing plant managers in making decisions to reduce costs and
maintain or improve their competitive position.
Results presented are based on economic-engineering-type cost studies
made in a sample of eight pea-freezing plants located in the Pacific
Northwest. Costs cited are not actual averages of current plant operation
costs, but are based upon labor and equipment standards of performance
obtained from time and production studies, equipment manufacturers' specifications and plant record data. These costs are somewhat lower than average
costs of the plants in the sample, but are attainable by the more efficient
producers and processors in the industry.
Pea freezing plant operations often are divided into several stages
or processes for purposes of cost determination. The following is a list
of these phases of the total operation as used in this study: (1) wining,
(2) receiving, (3) preparation, (4) packaging and freezing, (5) storage,
and (6) shipment of product.
- 2 -
This particular report is concerned only with costs and efficiencies
of number (4) above--freezing and packaging. Costs are shown for different rates of output under the following conditions:
(1) Packing into different size containers.
(2) Different lengths of processing season.
(3) Repacking and direct packing.
(4) Different methods used in processing.
Costs are included for a continuous capacity operation of that portion
of the freezing plant extending from the grading table through packaging,
freezing, casing, and placing the product in cold storage. Included in
these operations are the costs of all labor, equipment, buildings, and
package materials. Costs of electricity, depreciation, interest, insurance,
taxes, and maintenance and repairs are taken into account. Not included
are costs of the raw product, management, sales, and office.
RESULTS
Container Sizes and Costs
Size of package has a marked effect on plant operating costs (Figure 1).
If it is assumed that the entire plant output goes into one package size,
packaging and freezing costs for the 2 1/2-pound package are about 65 percent of the costs of the 10-ounce, the 50-pound bulk box 33 percent, and
the 1600-pound bulk box 24 percent. This further assumes that all products
are loose frozen in a belt tunnel.
The larger rates of output, regardless of package size, tended to have
lower costs per hundredweight of peas. This lower cost is most pronounced
when output is increased from 5,000 to 10,000 pounds per hour. At lower
rates, both equipment and labor have excess capacity. Increases in output
over the 5,000-pound level increases the efficiency with which both are
used. Beyond the 10,000-pound-per-hour rate, costs decline at a much slower
rate. This is because a single packaging and freezing line of 10,000-pound
capacity is relatively efficient, and increasing output beyond that point is
accomplished by duplicating complete lines. Also fixed costs--building,
equipment, and supervisory labor--represent only a small proportion of
packaging and freezing costs for the small-size containers. Variable costs-container materials, equipment operating costs and most labor costs--remain
constant per unit of output, regardless of rate of output.
Decreases in costs beyond the 10,000-pound per hour level are attributed to better utilization of supervisors, mechanics, engineers and some
savings in building costs. Had costs been included for relatively fixed
departments, such as management, sales, and office, decline in costs would
have been substantially greater with increases in rates of output as well
as in length of operating season.
The cost of container material was the most important single cost item,
varying from 78 percent of total costs for the 10-ounce operation to about
35 percent for the 60-pound bag (Table 1). Only in packaging into bulk containers--50-, 60-, and 1600-pound sizes--did costs of labor exceed 10 percent
of total packaging and freezing costs. Labor costs were less than equipment costs for all container sizes. Mechanized casing of 10-ounce packages
and use of nonsewed 60-pound bags made substantial reductions in labor costs
over hand casing and sewed bags. Use of these methods for a 20,000 pound
per hour rate of output and a season of 1,000 hours reduced the crew by
14 persons in the 10-ounce and 2 in the 60-pound bag operation. (Appendix
- 5 -
Tables 5 and 6 show crew organization and material costs for different
containers.)
Table 1. Comparative Costs of Packaging and Freezing
Peas in Different Size Containers, 1958 /1
Cost item
Labor
Equipment
Belt tunnel
Packaging, casing and
materials handling
Container materials
Building
TOTAL
10
ounce
Size container
50-pound 60-pound 1600-pound
2 1/2
box
bag/2
pound
box
(costs per hundredweight peas)
$ .26
$ .23
$ .17
$ .11
$ .14
.34
.34
.34
.34
.34
.20/3
.13
.06
.06
.05
2.83
1.64
.62
.29
.33/4
.02
.02
.02
.02
.02
$3.65
$2.36
$1.21
$ .82
$ .88
11
Assumes output of 20,000 pounds per hour, belt tunnel freezing, and
1000-hour season.
/2 Nonsewed bags.
/3 Automatic casing.
lit Assumes re-use of container materials - see Appendix Table 6.
Packaging and freezing costs cited above are intended to illustrate
the cost relationship between different size containers if only one size
were used. Actually, few plants package and freeze in only one size container. Container sizes used and proportion of pack going into each will
depend on available facilities and sales policies of the individual plant.
In plants using different combinations of container sizes for their
pack, the higher the proportion going into the larger sized containers,
the lower the costs (Figure 2). These estimates are based upon an
6
Figure 2. Freezing and Packaging Costs with
Different Container Proportions, 1958
$14
k(100 %10
oz.
oz.
25% 2 lb.
V 25% 50 lb.
So% 10
1150% 10 oz.
5Q% 50 lb.
1\100% 50 lb.
0
-1\0(
11—i700030,000
10,0
Rate of output per hour
(pounds of peas)
A Costs based upon these assumptions:
a. 1000•hour operating season
b. Belt-tunnel freezing
c. Automatic casing for 10-ounce
A
- 7 -
efficient 1,000-hour operation utilizing belt tunnel freezing for all peas
and automatic casing for the 10-ounce pack. Each of the four cost lines
shown in the chart are based upon low cost combinations of labor and
equipment with the freezing equipment operating at a constant rate o f
output. Efficient packaging and casing operations were selected for the
outputs shown and have a minimum of excess capacity. The chart is not
intended to portray a single plant with sufficient flexibility to produce
the volume of each combination of container shown at the indicated cost
for that combination. For example, a plant with an output of 10,000 pounds
per hour of 10-ounce and a like amount of 50-pound bulk would not be
equipped to pack 20,000 pounds per hour in either the 10-ounce or 50-pound
alone. A plant with such flexibility especially as it relates to the
smaller containers, would have substantially higher costs.
Length of Processing Season and Costs
Season's length for processing is usually fixed by climatic conditions
within an area and product characteristics. However, there is a certain
amount of flexibility in hours per season of plant operation when the
number of hours of operation per day can be varied. Where the hours of
plant operation can be increased, it is possible to reduce processing costs.
The longer the processing season the lower the costs at all rates of output
and for all container sizes (Figure 3).
Lengthening the season from 250
to 500 hours has a substantial cost reducing effect. Each additional
increase in season's length beyond 500 hours results in smaller cost reductions.
For example, by extending the season from 250 to 500 hours for a 10-ounce
belt-tunnel operation of 10,000 pounds per hour, costs, per unit can be
reduced by about 17 percent. If the season is lengthened to 750, 1,000,
and 1,250 hours, costs are reduced by only 6, 3, and 2 percent respectively.
Operations having the greater percentage of fixed costs are most
effected by season's length. As the season is extended, fixed costs are
spread over a greater season's output. The ratio of fixed to total costs
declines. This results in diminishing rates of reduction in the total cost
per unit of product.
Since the possibility of extending the season for any given commodity
is rather limited, some cost advantage may be gained by lengthening the
operating season through the processing of additional products. Maximum
cost reductions are obtained when the processing of these products utilizes
many of the same fixed items such as the freezing system, packaging and
casing equipment, building, and so forth.
Costs of Direct Packing and Repacking
Repacking from bulk containers into smaller cartons--10-ounce and
2 1/2-pound--is a common practice in the industry. This method of packing
has been adopted for two reasons. First, individual plants may not have
sufficient packaging capacity to initially pack their entire production into
small-size containers. Consequently, they pack a portion of their peas in
bulk containers and later repack into 10-ounce and 2 1/2-pound. The second
reason for repacking deals with sales. Some plants at time of harvest do
not have their season's output sold, so rather than pack into unlabeled
retail and institutional size containers, the unsold portion is packed in
bulk and repacked later on order.
Repacking is more costly than packing direct (Figure 4). This is due
to the extra handling and to the additional container costs not present
- 10in the direct packing operation. Repacked peas are first packed in bulk
containers--50-pound boxes in the example--and later are taken out of
storage and packaged in the final container. This involves one additional
round trip to storage and an additional packing operation, neither of which
are necessary when the product is packed directly.
When a portion of the season's pack is repacked, per unit costs
fall in between "all repacked" and "all packed direct." The greater the
Figure 4. Freezing and Packaging Costs for 10-ounce Packages With
Different Amounts of Repack from 50-pound Boxes, 1958 /1
/ All repacked
\J10,000 lbs./hr. direct
Balance repacked
Rate of output per hour (pounds of peas)
Costs based upon these assumptions:
a.
1000-hour freezing season
b. Belt-tunnel freezing
c. Automatic casing for 10-ounce
d.
Bulk boxes can be used an average of two times, but
liners only once.
e One 10-ounce packaging line with 10,000 pounds per hour
capacity used for all repacking. Length of season
varied to accommodate output.
portion packed directly at time of harvest, the lower the costs per 100
pounds of product.
Variation in Techniques Used in Freezing Plants
Pea freezing plants pack a common product, but in doing so use
different methods and techniques. Several types of freezing operations
and packaging and casing methods are used. Some of these appear to b e
considerably more efficient than others. Important differences are dis
cussed below.
Method of Freeze. Most of the costs cited earlier for the 10-ounce
operation have been based on belt tunnel freezing. This, of course, is
only one of several types of freezing methods used in the Northwest frozen
pea industry. Other methods include plate or contact freezing, tray
tunnel, and column freezing. The latter two are not as common in existing
plants or in new installations as either the belt tunnel or plate freezing.
Consequently, costs of freezing as discussed in this report will be confined to the two more common methods.
Freezing and packaging costs were only slightly lower for plate
freezing than for belt tunnel operations at all levels of output and for
seasons greater than 500 hours in length (Figure 5). The belt tunnel
method of freezing had substantially lower labor costs, somewhat lower
equipment and building costs, but had higher costs for package materials
which more than offset the other advantages (Table 2).
- 13 -
Table 2. Comparative Costs of Packaging and Freezing Peas
in 10-Ounce Containers by Plate and Belt Tunnel Method, 1958 /1
Cost item
Method of freeze
Belt tunnel
Plate
(Dollars per hundredweight peas)
Labor
Package materials
Freezing equipment
Other equipment and
building
Total
$ .44
2.51
.41
.23
$3.59
$ .26
2.83
.34
.22
$3.65
Costs based upon these assumptions:
a.
b.
c.
1,000 hour operating season
Output of 20,000 pounds per hour
Automatic casing
Cost difference also is reduced if a plant's output consists of
both plate and loose frozen 10-ounce products and uses the large wrap
designed for the larger package necessary for the loose frozen product.
This again can happen because of established sales policy. In this case
the larger wrap costs about nine cents more per hundredweight of peas,
This would more than offset the cost advantage shown for plate freezing.
(See Appendix Table 6 for packaging material costs.)
Freezing costs presented here are based on refrigeration equipment
firms' estimates of the physical requirements beginning with the engine
room through freezing for different rates of output. Current prices for
equipment and estimated costs for installation, maintenance and repairs,
depreciation, interest on investment and operating expenses were then
applied to the physical requirements. Labor requirements were obtained
- 14-
from time study and accounting record data and then converted to costs by
the use of current wage rates.
This procedure for determining costs permits development of synthetic
operations which are of better than average efficiency but typical of the
cost of a new installation. Costs determined by this means would be
below the average of existing installations but attainable by the more
efficient. Some of the assumptions used in the equipment cost determinations
are shown in Appendix Table 4.
Automatic Casing and Hand Casing. Automatic case filling machines are
relatively new to the industry and reduce costs substantially provided the
operating season is sufficiently long (Figure 6). At operating seasons in
excess of 400 hours the automatic caser is more economical than hand casing.
The reverse is true for seasons of under 400 hours. This relationship
exists for the 10,000 pound per hour operation cited in Figure 6 as well
as for other capacities ranging from 5,000 up to 30,000 pounds per hour.
Automatic casing costs per 100 pounds of peas are essentially the same for
all levels of output so long as they are in 5,000-pound increments. This
amount is an efficient operating level for one caser and one wrapper, so
increases in output mean an added caser with its attendant crew for each
5,000 pounds per hour increase in rate of output.
Increases in the operating season favor the automatic caser because
this technique involves a higher proportion of fixed costs than does the
hand method. Depreciation, interest and taxes remain relatively constant
regardless of the length of season, so increases in the hours of operation
tend to reduce costs per 100 pounds of peas. Costs of the hand casing
- 16-
operation are made up primarily of variable costs that change in direct
proportion to the total season's output.
APPENDIX
Basis of Costs
Cost estimates shown in this report are based on labor and equipment
standards developed from time and production studies made of actual plant
operations. In addition, other cost information has been obtained from
plant records, manufacturers' estimates and other sources.
Labor standards developed from time and production studies are shown
in Appendix Table 1. They represent the output of clean peas per man hour
of labor under conditions that are better than average, but below peak performance. Costs are derived from these standards by applying selected
wage rates prevailing in the industry during the 1958 packing season.
These wage rates are as follows:
Job
Form, fill, weigh, line, and code cases
and 50 lb. boxes, operate automatic caser;
quality control; tray filling.
Wage rate
per hour
$1.30
Package forelady
1.45
Load pallets; operate case sealer;
package supply and cleanup; load and
unload freezers; dump and return trays;
form, line, fill, and close 1600-pound
bulk boxes; fill and close 60-pound bags;
dump 50-pound boxes.
1.50
Operate plate freezer; tunnel operator
and defroster
1.60
Wrapper mechanic; mechanic; equipment
maintenance; assistant refrigeration
engineer.
1.85
Package foreman
Refrigeration engineer
1.95
2.15
- 17
Appendix Table 1. Labor Standards of Performance for Freezing, Packaging,
and Casing Green Peas, Oregon, 1958.
Job Classification
Operation
for which
used
Direct Labor
Operate Former and Filler
Operates and controls former,
filler and closer, gets flat
packages from carton and places
in forming machine
Operate Wrapper and Inspect Packages
Controls operation of wrapper,
removes over-under packages from
packaging line, and regulates the
flow of packages into the wrapper.
Wrapper Mechanic
Gets rolls of over-wrap from
temporary storage, keeps wrapper
supplied with over-wraps, makes
adjustments and services wrapper
Form Case (Hand)
Get, form and dispose of case
supply case filler with cases,
get supplies
Fill Case (Hand)
Get and position case for filling,
group and slide packages into case,
push case away from casing station
Form Case and Operate Automatic Caser
Get and form case, put on caser,
get supplies
Fold Flaps and Code Case
Fold flaps of case to close,
code case with hand stamp and
push case toward sealer and
compressor
Load Pallet and Operate Sealer
Get and stack cases onto pallet,
get and place empty pallets, and
service, adjust and regulate case
sealer and compressor
Load Pallet
Get and stack cases onto pallet,
get and place empty pallets.
Fill Tray
Get and place tray, group and
slide packages onto tray, move
full tray
Lbs. of
clean peas
per man-hour
10-ounce -Belt Tunnel
10-ounce -Plate
2 1/2-lb - Belt Tunnel
10,125
10,125
10,050
10-ounce -Belt Tunnel
10-ounce - Plate
2 1/2-lb - Belt Tunnel
5,070
5,070
10,050
10-ounce -Belt Tunnel
10-ounce -Plate
2 1/2-lb - Belt Tunnel
10,125
10,125
20,100
10-ounce -Belt Tunnel
10-ounce -Plate
2 1/2-lb - Belt Tunnel
3,600
3,600
6,330
10-ounce -Belt Tunnel
10-ounce -Plate
2 1/2-lb - Belt Tunnel
2,775
2,775
5,130
10-ounce -Belt Tunnel
10-ounce - Plate
5,550
5,550
10-ounce -Belt Tunnel
10-ounce - Plate
2 1/2-lb - Belt Tunnel
6,015
6,015
12,030
10-ounce - Belt Tunnel
10-ounce -Plate
2 1/2-lb - Belt Tunnel
5,120
5,120
7,400
50-lb box - Belt Tunnel
60-lb bag - Belt Tunnel
10-ounce - Plate
Cont. next page
13,100
12,000
2,550
18Appendix Table 1, continued
Job Classification
Operation
for which
used
Direct Labor Cont.
Load Freezer
Get and place trays in freezer,
open and close freezer doors and
adjust controls of freezer
Unload Freezer
Take trays out of freezer and
place on conveyor, open and
close freezer doors and adjust
controls of freezer
Dump Tray
Get, dump and dispose tray,
operate belt to casing table
Adjust Flow of Packages to
Automatic Caser
Regulate flow of product from
tray dumping station into single
line lead-in conveyor to automatic
caser
Return Empty Trays
Take full tray racks of empty trays
from tray dumping station to tray
filling station, return empty
tray racks to tray dumping station
Form and Line: Box
Get and form box, tape bottom
closed, line box by use of
mandrel, dispose of lined box
and get supplies
Form and Line Bulk Box
Get pallet, frame, shook and
liner, assemble box, line, and
get supplies
Fill and Weigh Box
Get empty box and place under
filler, operate controls, fill
to desired weight and push filled
box to closing station
Close and Code Box
Shake full box to settle peas,
close liner, fold flaps of box,
tape box closed, code box and
push away from station
Fill and Close Bag (Unsewed)
Get bag, fasten over filler,
operate controls to fill bag,
remove bag from filler, tuck in
valve cover, put bag aside and
get supplies
Lbs. of
clean peas
per man-hour
10-ounce - Plate
6,450
10-ounce - Plate
7,050
10-ounce - Plate
6,600
10-ounce - Plate
6,600
10-ounce - Plate
10,125
50-lb box
Belt Tunnel
1600-lb bulk boxBelt Tunnel
3,950
5,000
50-lb box - Belt Tunnel
10,000
50-lb box - Belt Tunnel
7,000
60-lb bag - Belt Tunnel
10,140
Cont. next page
- 19 Appendix Table 1, continued
Operation for
which used
Direct Labor Cont.
Job Classification
Lbs. of clean
peas per man-hour
60-lb bag - Belt Tunnel Fill and Close Bag (Sewed type) Get bag, place under filler,
operate controls to fill bag to
desired weight, remove from filling station, shake peas to settle,
fold top of bag for sewing, move bag
through sewing machine, dispose of
bag and get supplies
1600-lb bulk box -
Fill and Close Bulk Box
Belt Tunnel
Adjust box under filler, operate
controls to fill, close, tie poly
liner and code box
Repacking from 50-lb
Dump Box
boxes to 10-ounce
Get and open 50 lb box, dump,
fold and stack boxes and liners
5,280
5,000
4,000
Supervisory and Indirect
Package Foreman
All
30,000
Package Forelady /1
10-ounce - Belt Tunnel 10-ounce - Plate
2 1/2-lb - Belt Tunnel 50-lb box - Belt Tunnel
30,000
30,000
30,000
30,000
Package Supply and Cleanup
10-ounce - Belt Tunnel 10-ounce - Plate
2 1/2-lb - Belt Tunnel 50-lb box - Belt Tunnel
60-lb bag_- Belt Tunnel
1600-lb box - Belt Tunnel
Refrigeration Engineer
All
30,000
Assistant Refrigeration Engineer
All
30,000
Quality Control
All
10,000
Equipment Maintenance /3
10-ounce - Belt Tunnel 10-ounce - Plate
2 1/2-lb - Belt Tunnel
30,000
30,000
30,000
Belt Tunnel Operator
and Defroster
All Belt Tunnel Operations
10,000
Plate Freezer Operator
10-ounce - Plate
30,000
10,000
10,000
20,000
20,000
30,000
20,000
/1 This job is performed by the package forzman for rates of output under
15,000 lbs. per hour for 10-ounce and 21/2-pound and 25,000 pounds for
50-pound box.
/2 For rates of output under 15,000 lbs. per hour this job is performed by
the refrigeration engineer.
/3 For rates of output under 15,000 lbs. per hour for 10-oz. and 22-1b.
operations, and 30,000 lbs. per hour for 50-1b. box, 60-1b. bag and
1600-1b. box operations this job is performed by other than packaging
and freezing personnel.
- 20 -
Equipment standards were obtained from production studies made during
actual plant operation and from equipment manufacturers' estimates and
specifications. These standards have been used to determine the number of
pieces of equipment required for different rates of output (Appendix Table
2). Estimated fixed and variable costs for each piece of equipment as shown
in Appendix Tables3 and 4 then were applied to obtain total equipment
costs.
The following is an example of the,calculations made to develop the
costs of labor, equipment and container materials for freezing and packaging peas into 50-pound bulk boxes. Operations in this illustration start
with freezing and end with the filled 50-pound box placed on a pallet ready
to be transported to storage. Building costs and costs of moving the
cased product to storage are excluded in the example. It is assumed that
the plant output into this size container is at the rate of 20,000 pounds
per hour for a 1,000 hour season.
Crew requirements are obtained by dividing each of the applicable labor
standards of Appendix Table 1 into the rate of output 20,000 pounds per
hour. The following is the crew calculated in this manner:
No.
Workers
Job
Package foreman
Package supply and cleanup Refrigeration engineer Assistant refrigeration engineer Quality control
Belt Tunnel operator and defroster
Form and line box
Fill and weigh box
Close and code box Load pallet
1
1
1
2
2
6
2
3
-21
Wage rates shown on page 16, plus an additional 12 percent for
employer costs are then applied to the above labor and multiplied by
1,000 hours--the assumed length of the operating season. The total labor
cost for the 20,000,000 pound output (20,000 pounds per hour x 1,000 hours)
is $34,216.
Equipment costs can be derived from Appendix Tables 2, 3, and 4.
Appendix Table 2 shows the number of pieces of equipment required for
a 20,000 pounds per hour 50-pound box operation. Costs of operating this
equipment shown in Appendix Table 3 are then applied to the equipment list.
For example, two sets of scales are required for weighing. Their annual
cost amounts to $33 each for fixed charges and $10 for variable costs or
a total of $43 each. Total equipment costs other than freezing amount
to $774.
Referring to Appendix Table 4 the estimated annual fixed cost for
a 20,000 pound per hour belt freezing installation is $44,477. Variable
costs for a 1,000 hour season amount to $23.01 per hour ($6.10 + $.06 +
$16.85) or $23,010. Total fixed and variable costs are $67,487.
Container costs as shown in Appendix Table 6 are estimated to be
62 cents per hundredweight of peas packed or $.62 x 20,000 hundredweight
for a season's cost of $124,000.
Total of the above items is as follows:
Labor
Equipment (other than freezing)
Freezing equipment
Container
Total
$ 34,216
774
67,487
124,000
$226,477 or $1.132 per
hundredweight
- 22
Appendix Table 2. Equipment Requirements for Packaging and Freezing Peas
for Different Rates of Output by Container Size
and Method of Freeze, 1958. 1/
Item of equipment
Hopper
Former, filler, closer
Coder
Metal detector
Conveyor 10' live belt
Check wt. scales (3 lb.)
Wrapper
Case forming table
Chute for empty case
supply 15'
Casing table
Conveyor 25', live belt
Sealer & 12' compressor
Sealer & 20' compressor
Automatic caser
Screw conveyor
Cluster breaker
Hopper
Former, filler, closer
Coder
Metal detector
Conveyor 10' live belt
Check wt. scales (3 lb.)
Wrapper
Tray filling table
Conveyor 100' dead roller
Tray dumping belt
Casing table
4' roller conveyor
Case forming table
Chute for empty case
supply 15'
Conveyor 25' belt (live)
Sealer & 12' compressor
Sealer & 20' compressor
Automatic caser
Trays-30-10 ounce alum.
Tray rack--40 tray cap.
Hopper
Former, filler, closer
Coder
Conveyor 10' live belt
Number pieces of equipment required for
different rates of output
(Pounds clean peas per hour)
5,000 10,000 15,000 20,000 25,000 30,000
24 - 10 ounce - belt tunnel operation 2/
3
3
2
2
1
1
3
3
2
2
1
1
6
5
4
3
2
1
6
5
4
3
2
1
12
10
8
6
2
4
6
5
4
3
2
1
6
5
4
3
2
1
4
3
1
2
1
1
1
1
1
1
1
1
1
1
1
3
1
1
1
2
2
2
5
4
3
5
4
3
2
5
4
3
2
1
1
2
2
1
1
5
4
3
2
2
3
2
1
3
2
2
1
24 - 10 ounce - plate operation 2/
3
2
1
2
3
2
2
1
5
4
3
2
5
4
3
2
15
12
9
6
5
4
3
2
5
4
3
2
5
4
3
2
6
4
4
2
10
8
6
4
10
10
6
6
6
3
6
3
3
3
3
6
6
18
6
6
6
6
12
12
12
12
10
4
4
2
2
1
1
2
3
2
1
1
6
5
4
3
1
2
3191
2660
2128
1596
1064
532
17
20
14
10
7
4
12 - 21 lb. - belt tunnel operation
3
3
2
2
3
3
2
2
1
1
3
3
2
2
1
1
2
2
1
1
2
1
1
Continued next page
23Appendix Table 2, continued
Number pieces of equipment required for
different rates of output
(Pounds clean peas per hour)
Item of equipment
5,000 10,000 15,000 [20,000 125,000 30,000
belt tunnel operation cont.
3
3
2
2
3
3
2
2
3
3
2
2
-
Check wt. scales (3 lb.)
Wrapper
Case forming table
Chute for empty case
supply 15'
Casing table
Conveyor 25' live belt
Sealer & 12' compressor
Sealer & 20' compressor
Screw conveyor
Cluster breaker
Hopper
Filler
Forming table
Chute for empty box
supply 15'
Lining mandrel
Conveyor dead roller 20'
Scales
Taping machine
Screw conveyor
Cluster breaker
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
Hopper
Filler (Automatic)
Filler (hand operated)
Scales
Belt conveyor (6' live)
Sewing machine
Screw conveyor
Cluster breaker
1
1
1
1
1
1
1
1
Hopper
Filler
Screw conveyor
Cluster breaker
1
1
1
1
1
1
3
3
2
2
1
3
3
2
2
1
3
3
2
2
1
1
1
1
1
1
1
1
3
3
2
2
1
3
3
2
2
1
-lb. box belt tunnel operation
3
2
2
1
3
3
2
2
1
2
2
3
1
1
1
1
2
1
1
60-1b. bag
1
1
1
1
1
1
1
1
0
1
1
1
1
3
2
2
3
2
2
3
2
2
2
3
2
6
4
4
3
2
2
3
2
2
belt tunnel operation 3/
3
2
2
3
2
2
3
2
2
2
3
2
3
2
2
3
2
2
3
2
2
2
3
2
- belt tunnel operation
3
2
2
3
2
2
3
2
2
3
2
2
1/ Does not include refrigeration equipment--see Appendix Table 4.
2/ Includes equipment for both hand and automatic casing.
3/ Includes equipment for using tuck-in bags as well as bags which
require sewing.
3
3
6
3
3
3
3
3
3
3
3
3
3.
3
3
3
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co co
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$4
o
cnI 0
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A '0 .--.
11 o., cd -0
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1111 44 co 4j
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-
26Appendix Table 5. Crew Organization for Packaging and Freezing Peas
in Different Container Sizes and for Different Rates of Output, 1958 /1
Size container
Job
10 ounces
Belt
Plate
frozen frozen
8
2
4
2
2
3
1
1
1
1
1
1
19
1
1
1
1
12
13
Freezing
3
Packaging
8
Casing and pallet loading
1
Storing
1
Equipment maintenance
1
Quality control
1
Cleanup and supply
1
Supervisory
1
6
29
Total
2
3
6
1
1
1
1
1
16
Freezing
Packaging
Casing and pallet loading
Storing
Equipment maintenance
Quality control
Cleanup and supply
Supervisory
Total
24
6
16
1
3
2
2
2
56
4
6
12
1
3
2
2
2
32
Freezing
Packaging
Casing and pallet loading
Storing
Equipment maintenance
Quality control
Cleanup and supply
Supervisory
Total
34
9
24
1
4
3
3
2
80
5
9
18
1
4
3
3
2
45
Freezing
Packaging
Casing and pallet loading
Storing
Equipment maintenance
Quality control
Cleanup and supply
Supervisory
Total
60-pound
50-pound non-sewed 1600-pound
211
bags
box
pound box
(number in crew)
5,000 pounds per hour
2
2
2
1
4
2
1
1
4
1
1
1
11
13
10,000 pounds per
2
2
6
2
1
1
8
13
20,000 pounds
per hour
4
4
4
2
11
4
2
2
13
1
1
I
2
2
1
1
1
1
1
2
13
22
29
50,000 pounds per hour 5
5
5
3
16
6
3
3
18
1
1
1
3
3
3
3
1
2
2
1
2
2
17
32
40
10
17
5
12
1
111.0,10i
Assumes the following:
a. Automatic casing
b. Product handled and stored on pallets
c. Unless otherwise noted products are belt frozen.
3
2
1
24
-27 -
Appendix Table 6. Costs of Packaging Materials for Frozen Peas, 1958
Container
Bulk
24 24
60 lb. 60 lb. 1600
12
10 oz. 10 oz.
2 1/2 50 lb. sewed nonsewed lb.
loose
plate
box
bag
bag
freeze freeze pound box
(Cost per hundredweight peas)
Carton
(5 x 4 x 1 1/4")
(5 1/4 x 4 x 1 1/2")
(9 1/2 x 5 1/2 x 2 1/2")
$1.52 $ ---
1.67
OMANI
Wrapper
(12 x 7 3/8")
(13 x 8")
(17 x 13 1/2")
ON WM
.96
--
ler
•••
•••
.67
.42
0000
1•11
•n•
.50
.36
Box
(16 3/8 x 10 3/8 x 14 1/4")
(bulk box, frame and liner)
--
.49/2
410
.33 /3
Liner
(17 1/2 x 10 1/2 x 28") TOTAL COSTS
$
$
$
$
.58
Case
(15 3/4 x 8 3/8 x 5 1/2")
(16 1/2 x 10 3/4 x 4 1/2") (16 1/4 x 9 5/8 x 10 1/4")
Bag
(16 x 5 x 38")
(16 x 5 x 34")
L.
--
•n••
IMO*
11000
$2.52 $2.84 .13
.1011.
0.00
00*
$1.64 $ .62
.26/2
-$ .26
/1 Includes the following allowance for shrinkage:
a. Bags and liners - 0.25 percent.
b. 10-ounce packages - plate 4 percent and loose 2 percent.
c. 2 1/2-pound packages - 2 percent.
d. Wrappers 4 percent and cases 1 percent.
/2 Includes cost of tape and twine.
/3 Years use life - frame and box 4 - liner 1.
-.29
$ .29
$ .33