At Færch Plast quality is considered a way of living - as hygiene is considered something of a religion !
A tobacco company where smoking is prohibited in the production areas. A plastics manufacturer who likes natural raw materials and builds without plastic. A factory with hygiene standards better than most hospitals. Are you confused? There's no need to be. Visit the Færch Plast Ltd factory in Holstebro, Denmark and everything will become clear. There is a reason, of course, for these three apparently contradictory factors. The first is that the Færch company used to be a tobacco producer. It now produces plastic. The second derives from the attitude of Færch's charismatic MD, HEINRICH KÜSCH. The third explains the reason behind the Færch success: if you produce plastic packaging for food products, the plastic has to be as clean as the food itself. At Færch's no compromises are made. When HEINRICH KÜSCH introduced the company's stringent hygiene regulations, a number of employees rebelled - in particular some of the female staff. The hairnet ruined their hairstyle and the male staff thought having to wash their hands every time they entered the factory was a little excessive. It took just one week before everyone had complied with the rules. The new initiative resulted in one sacking - not one of the employees, but an external supplier. One year later, employees voted Færch's the best work place in Denmark in a nationwide competition arranged by one of Denmark's leading newspapers. The company policy has clearly paid off. When representatives from large potential customers visit the premises to negotiate the delivery of CPET trays for ready meals, they often enquire about the company's ISO 9000 certificate. HEINRICH KÜSCH often replies: "We haven't applied for it yet because we do not feel it's necessary." However preparations are taking place and upon completion Fæerch will consider an application for certification. After a tour of the factory, a customer usually have no problems in placing orders with the company. "We're not just a plastics factory. We're an integrated part of the food industry we serve," HEINRICH KÜSCH says. "In the food industri, hygiene is absolutely vital." HEINRICH KÜSCH joined Færch Plast Ltd. in 1985 becoming its managing director in 1987. The company has since become number one in Europe in its field. With a turnover of close to DKK 350 million - USD 50 million - 75 percent of the output is exported to three main geographical areas. One third goes to other Scandinavian markets and one third goes to Britain where Marks and Spencer's brand, St. Michael, is the main purchaser. The remaining third goes to other European markets. The philosophy at Færch is simple: to be the best!
1990's consumers do not choose products from supermarket shelves haphazardly. Appearance, presentation and packaging are all vital ingredients for healthy sales. "We're talking about image and image is the key to higher sales," says Ole Gade, the young sales and marketing director who was recruited by KÜSCH himself. "Packaging has much to do with image - provided the product is a quality product. Ours is. We don't place such importance on our hygience policy just for show. Our products in CPET plastic (the trade jargon for plastic designed for microwave ovens with the ability to withstand heat up to 220 degrees centigrade) have the lion's share of the European market. When you have a quality product, the rest is image and hard work from the designers. Sometimes we design up to seven dummies for a certain design before production begins. We co-operate closely with our customers, making sure that the packaging fits all the specifications." During 1997, Fæerch will invest more than USD 10 million in plant and equipment, including a new building which will house a state-of-the-art extruder. This sophisticated piece of machinery turns plastic granulate into plastic foil, an essential component in the company's output. The extension will ultimately double production. "We're extending our stock facilities, too," explains Ole Gade. "At the moment, we hold stock for about three months to safeguard against the worst scenario - in our case fire. This is why the factory is one of the best fire-protected buildings in Holstebro."
The concern with stock reflects the company's delivery policy: once an order is placed, delivery must take place precisely on time - not one minute late. "Our products are intended for fresh food. If a food producer is ready to pack their produce, our product must be there or tonnes of food may have to be thrown away," says HEINRICH KÜSCH. "There can be absolutely no excuse for being late. We have never been late and as long as I'm charge, we never will."
The KÜSCH style at Færch does not stop at production, sales and quality controls or even the attitude towards hygiene which Heinrich Kiisch has turned almost into a religion throughout the company. Going to work has to be exciting, KÜSCH believes. This is one of the reasons why the factory - internally and externally - does not resemble a factory, but rather an art museum. The architecture is appealing with expressionist art designed to enhance the working environment.
There is only one problem - the staff toilets and changing rooms. They have become too small and crowded. "A few years ago, they successfully accommodated 160 employees. Now, with a workforce of more than 300 employees, I'm ashamed. So the new building will have brand-new staff areas which will enhance what our work is all about - quality. Quality combined with job satisfaction."
Packaging for the modern consumer
Færch Plast has grown into one of the most modern and efficient manufactures of plastic packaging in Europe today. We employ highly advanced production equipment, and production takes place in optimum hygienic conditions. The raw materials used are all in accordance with FDA and/or EGA guidelines, and production takes place within the framework of the most recent EC directives. The entire company is currently aiming to achieve ISO 9000 quality approval. Our well-equipped quality control unit carries out regular checks to ensure that our products live up to agreed specifications, and we are constantly engaged in product development and testing of new materials and compositions, with a view to offering our customers new, exciting packaging systems. Owing to current concern for the environment, we now devote considerable research effort into packaging made of monofoils with improved barrier and sealing properties. Our Development Department explores new types of packaging to add to our standard range, as well as working alongside customers to design specific types of packaging - using the latest CAD/CAM technology to enable both customers and ourselves to evaluate the results at all stages. And all this is possible because the employees of Færch Plast - technical staff and sales staff alike are experts who concentrate on supplying topclass packaging to meet requirements all the way from production to customer and back again!
The consumers of the 1990s are making everincreasing demands with regard to the development of new packaging for food products, choosing food products which attract them due to the packaging displayed on shop shelves. The more visible a product is, the better its image will be conveyed - and image is the key to achieving better sales. Consumers decide who wins the battle for space on shop shelves, and their judgement is both quick and without mercy. Purchasing patterns these days are affected by the family's wish to spend more time together and cultivate their hobbies, making the distance between food products and the dinner table ever shorter. Changes in lifestyle are currently leading to increasing requirements with regard to the quality and presentation of food products, which means that the properties and design of the packaging used are more vital than ever before. Does the packaging seem hygienic, and is it attractive? How do you open it? Do the contents look inviting? And last but not least - what about the environment? Does the packaging meet increased demands with regard to reuse and/or recycling? Færch Plast packaging lives up to all these demands. It is designed for the consumers of the 1990s, and aims to protect the fragile world we live in.
A wide range of leading food manufactures and supermarkets throughout Europe already use Færch Plast packaging, and are fully aware of its considerable and undoubted qualities. They chose Færch Plast in order to stay at the forefront of packaging developments. The use of our products by these companies has provided us with considerable expertise with regard to packaging for many different types of food products. As a result, we can now meet virtually all the requirements made by customers on their packaging partners both now and in the future. Our experience is also invaluable in providing advice regarding integrated systems for packaging and sealing machinery and sealing film. One of Færch Plast's strengths is the wide range, which consists mostly of standard packaging designed to suit fresh, frozen or heat-treated food products. We have a great number of different designs and sizes for each packaging requirement, and our modern, high-tech production methods ensure that customers are supplied with packaging that meets all operational and filling requirements both now and in the years ahead.
R. Færch Plast A/S
Rasmus Færchs Vej
Postbox 1040
DK - 7500 Holstebro
Denmark
Tlf. +45 99101010 Telefax +45 99101099