The Challenge

More Efficient Workflows for Handmade Gourmet Sweets

Situated on the Danish island of Bornholm, Karamel Kompagniet enjoys sweet success with its handmade gourmet caramels. Production continues to grow every year. However, the production of caramels involves a great deal of heavy lifting, which takes its toll on the backs, lumbar areas and shoulders of the employees. For this reason, Karamel Kompagniet has invested in two different lifting aids to sweeten the day-to-day activities of the employees.

Thousands of tons of caramels are produced every day by Karamel Kompagniet in Rønne. The caramel recipe was handed down to Anna Knightbridge, owner of Karamel, Kompagniet, by her grandmother, who used to prepare these delicious treats for family and friends. The recipe has been in the family since 1894. In 2004, Knightbridge founded the company Karamel Kompagniet, which employs up to 25 workers in peak periods. "We are producing at maximum capacity and every year we set new sales records," reports Anna Knightbridge, Owner and Managing Director of Karamel Kompagniet. Nevertheless:

• "The production of caramel sweets is hard work and involves a lot of heavy lifting. In the long term, this can take its toll on the backs and muscles of our employees," says Knightbridge
• Heavy pots of caramel mass weighing 70 kg must not only be pushed through the production facility, but also tilted so that the mass flows onto the cooling table – an extremely strenuous task
• Carrying the heavy lump of caramel to the roller is a 2-man job.

"For this reason, we have invested in two mobile lifting aids from Hovmand to do the heavy lifting for us," continues Managing Director Knightbridge. "The mobile lifting aids simplify our work processes significantly. Our production no longer involves any heavy lifting or strenuous tasks. As a result, our working environment is improved and our working day is more productive. In a company where up to 100,000 6 to 8 g caramels are produced by hand every day, this is an enormous help.

The Solution

A Tipper Takes on the Heavy Tasks

The company has invested in two different lifting aids from Hovmand. The first is equipped with a special stirring tank, which is used every day in the production facility. The cooked caramel mass in the caramel cooker weighs around 60 kg. It is filled into the pot on the lifter, which is then pushed onto the cooling table – all this without heavy lifting. A sophisticated tilting device enables the staff to quickly and effortlessly rotate the 70 kg stirring tank to pour the caramel onto the cooling table.

The ”Gyro” Makes Work Even Easier

As soon as it has cooled, the lump of caramel on the cooling table is placed in the roller. Until now, it was a 2-man job to lift the heavy lump of caramel and carry it to the roller. On the basis of her positive experiences with the aforementioned vessel lifter, Anna Knightbridge approached Hovmand with this challenge. Together with a competent sales colleague, she designed a new lifting aid to solve the problem.

Its flexibility and ability to rotate around itself earned the new lifting aid the nickname "gyro" from Karamel Kompagniet employees. The "gyro" is also a mobile and flexible lifting system, that can be equipped with either an arm or a plate as required. This is another rugged and flexible lifting solution, which is tailored to suit the specific lifting task with different tools.

Benefits

The Lifting Aid Makes Light Work of Heavy Lifting

The "gyro" manoeuvrable lifter has made transferring the caramel mass from the cooling table to the roller much simpler. The work can be carried out easily by a single production team member – without physical exertion. The employee carefully pushes the caramel mass onto the plate attached to the lifter. The lifter is then moved to the roller, into which the caramel mass is slowly lowered by means of a special lifting- and lowering system. This used to be a difficult, 2-man process.

For the production of its gourmet caramels, Karamel Kompagniet also requires large amounts of sugar. The sugar is delivered in heavy and unwieldy 25 kg sacks. Here, too, the "gyro" steps in to transport the sugar sacks from the warehouse to the production facility. It removes the need for difficult and cumbersome lifting tasks to be done by employees – a win-win for the working environment and the workforce.

Sweet Success of the Caramels Continues

Karamel Kompagniet enjoys record sales every year. As a result, expectations for 2021 are high, and plans are afoot to expand production even further. Increased production capacity will be required, but according to Anna Knightbridge, it can be achieved. She explains: "In order to keep up with production, we may have to contact Hovmand with regard to supplying an additional lifter with boom."