Challenged to find ways to differentiate in the extremely competitive corrugated packaging marketplace, this leading producer deploys the Mars Air Systems air curtain solution to contribute to a cleanliness standard that helps them pass the most stringent of audits and sets them apart from other food casing providers. In a 62,000 sq. ft. facility, Empire Packaging and Displays produces $50M annually in corrugated boxes and displays, which give food producers the means to package, ship and display their products in the hygienic envelopes that are in demand in today’s highly regulated food safety environment. Once a user of plastic strips to guard their dock doorways, the Empire team realized “plastic strips were the number one hazard in the factory – even more than the equipment we used,” said co-owner Hal Mottet, “because they were constantly dirty, had turned cloudy after a month of use, and were often pushed aside by staff who found them cumbersome and intrusive to their work.” The Empire team quickly recognized that for a few dollars in electricity per month they could achieve a safe and effective barrier to keep dust, debris and flying insects out of the plant with the added bonus of more productive climatic conditions for workers.
After years of struggle to function well and work amid the “rules” the staff had put into place to avoid injuries with the tangled and visibility-reducing plastic strips, Empire put safety first by installing three 14-foot dock door Mars air curtains. “On hot days the plant definitely feels cooler with the Mars units riding shotgun over the dock doors. Neither shift is using makeshift methods to move the plastic strips out of the way now that they’re gone and visibility around the dock doors is at all-time highs which eliminates our worries about worker safety. The American Institute of Baking International (AIB) agrees that the Mars air curtain solution is far superior and helps us meet the cleanliness standards so we can pass their rigorous audit year after year,” says Mottet. “And having that credential from AIB is instrumental to many of the clients we serve and one we consider critical to our continued success.”
As P&Gs third largest diaper plant in the world, responsible for exporting 60 percent of its production to Europe, Asia and the Mid- East, this Cairo-based plant often leads as one of Egypt’s top American business success stories. Set in an area known for legendary dust storms that transfer accumulated debris from the far reaches of the Saharan Desert, on any typical day air quality measurements routinely record dangerously high levels of suspended particulate matter. Mars Air Systems to the rescue. With the installation of over 100 Mars air curtain units in a plant hosting over 1200 workers, the result was an effective embargo on bad air and dust from blowing in doorways and entryways. Deploying the Mars comprehensive facilities-wide approach to controlling both loading dock entries and doorways with a directed stream of air, facility managers were assured that unpredictable climatic conditions would be forced to surrender to the power of the Mars air curtain and their invisible shield of protection.
Campbell Soup Company, one of the largest food companies in the world, operates a sprawling, 2.4 million-sq.-ft. facility on a 949-acre parcel, which includes operating a cooler/freezer storage unit 24 hours/day alongside a 8’x16’ heavily trafficked forklift entrance with a fast-acting vertical-lift door. The hot, humid warehouse conditions collide with the cold, dry-storage area air which produces condensation and pools of water at the base of the freezer -- both inside and out. Water also flowed from the freezer opening directly into the walkways that hosted both foot and forklift traffic. The Mars Air Systems Engineering team isolated the precise area that needed an air burst then installed a bundle of door-activated air curtains and air diffusers right at the forklift entrance. The air curtain’s forced-air action stabilized cold area temperatures by creating an air seal which effectively evaporated most surface condensation and eliminated pools of water in the walkway.
Uncontrolled relatively humidity levels in manufacturing can damage products during production and strike a blow to the top line. At the 1M sq. ft. Illinois-based Schrock Cabinetry laminated cabinet plant, dozens of expansive loading dock doors and entry doors gave rise to an unwinnable cat and mouse game with plant operators who tried to keep plant temperature and humidity stable enough so the laminated finish didn’t crack. Knowing Mars has repeatedly provided the right answer when large industrial operators need no-fail solutions to vexing humidity, condensation or pooling water, the Schrock team installed a series of air curtains. The bank of units now stand guard and contribute to creating the consistent climate conditions so their production teams can focus on making the semi-custom cabinets that have given them a national reputation.
When you’re as successful as Westmoreland County Food Bank because you serve 7,200 families a month and operate a 40,000 sq.ft. facility that processes 8.6 million pounds of food a year, your food storage equipment needs to work flawlessly. For Westmoreland, facility limitations forced the freezer and evaporator to sit side-by-side which led to a healthy dose of humidity leading to ice and frost on the floor outside the freezer doorway – a safety hazard for both forklifts and workers on foot. When it’s too important or costly to be anything other than right, Mars Air Systems is the team you want on your side. Mars has been repeatedly the source for answers when large industrial and foodservice operators need no-fail solutions to vexing humidity, unwanted condensation or accident-provoking pools of water. Deploying air baffles to ride shotgun along side the series of air curtains gave the Westmoreland workers the means to ward off the flowing water that had been a source of slippage, falls and worker injury.