Tayto Group produces over 2 million packs a day at its factory in Scunthorpe. The application of air conveying systems for snack foods is increasingly popular among both large and small manufacturers. Apart from the lower cost of installation, the main benefit is the flexibility it affords to plant design and layout.

The project

Tayto makes numerous pack formats and so must be able to quickly direct the bagged product to the appropriate multi-packing machines. JACOB delivered the pipework system for Tayto, using the advantage of modular design to optimise plant layout.

The implementation

The modular pipework air conveying system designed by JACOB for Tayto is believed to be the largest installation of its kind in the UK. It is based on 200 mm diameter thinwalled 1 mm thick stainless steel pipes measuring up to 2.0 m long, each with a precision machine lipped end designed to accept a Keltan (EPDM) `U´ shaped seal and pull ring connector for an air tight connection. The bi-directional air conveying lines have speed controls to cater for variations in product weight. The installation process was quick with minimal disruption to the operation of the plant. The majority of the JACOB ducting and pipework is located high above the plant but still accessible.

The unique aspect

The JACOB stainless steel modular pipe sections feed products to multiple packing lines up to 44 metres from where the crisps and snacks are bagged. By using the air conveying system rather than conventional mechanical conveyors, Tayto is able to save space and have much greater flexibility in how they feed the packing lines. The connections of the system allow earthing continuity to eliminate static electricity and the whole system is designed to optimise product flow. A pressure certified connection is created which has the advantage of providing electrical conductivity with the added benefit of being ATEX compliant.

The thin-walled ducting sections are easily dismantled and re-connected using the QUICK CONNECT pull-ring system designed and manufactured by JACOB. Air movement within a JACOB pipeline is enhanced with the smooth-pressed bends, which assist airflow with the minimum of resistance. Standard accessories include inspection doors, visualisation ducts, diverters, product-control and air-control valves, all manufactured to high tolerances. With pipework diameters from 60 mm to 1600 mm and a comprehensive range of forks, bends, T pieces, valves and distributors, JACOB modular pipework is ideal for creating an efficient and flexible system, which can adapt to changing requirements.

The company

Tayto Group is the UK’s largest family-owned manufacturer of crisps and snack foods with the Golden Wonder, REAL and Mr Porky brands. It’s Scunthorpe factory makes products ranging from 18 to 175g grams that are packed either as single bags or mutli-packs.

Case Study: Tayto

JACOB pipe systems take less time to install than conventional systems.
Using the QUICK CONNECT pull-ring makes it even faster. This is a great advantage!

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JACOB sets standards in food safety. Our new FOOD GRADE line of products complies with both the European EC 1935/2004 regulations and the American FDA guidelines.

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Foreign particles in a product are not acceptable in many industry sectors. JACOB has succeeded in incorporating minuscule particles in the compound that the seals are made of.

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JACOB’s wear protection range extends the service life and in addition the cost-effectiveness of your industrial plants. Various polyurethane linings make the inside of the pipework sections resistant to hard and abrasive substances. 

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