SUCCESS STORY
Automated Weighing and Bagging System for Catfish ProducerAUTOMATED WEIGHING AND VERTICAL BAGGING LINE FOR FROZEN CATFISH FILLETS
When a U.S.-based catfish filet processor approached SIGMA, they were preparing to enter the retail market for the first time. While they already had a packaging system in place for a bulk, bag-in-box format used in foodservice, they lacked the equipment needed for retail-ready packaging. They needed a partner who could help them expand their packaging capabilities — fast.
The goal? To design and implement a fully automated weighing and bagging system capable of retail-ready packaging for their frozen 2- and 4-pound catfish filet bags. By combining in-house engineering, strategic sourcing, and hands-on collaboration, SIGMA delivered a customized solution that fit the client’s limited floor space, hit production targets, and helped them successfully launch into retail.
The Challenge
TRANSITIONING FROM FOODSERVICE TO RETAIL
Historically, Harvest Select served the foodservice market with bulk packaging, but entering the retail space meant shifting to consumer-facing packaging, smaller unit sizes, and a much more automated production environment. Without existing retail bagging equipment or internal expertise, the client needed a partner who could help them make this leap quickly and successfully.
LIMITED VERTICAL SPACE IN THE FACILITY
With only 13 feet of vertical clearance, the client’s facility posed a challenge for integrating a multi-component packaging line. Standard equipment configurations wouldn’t fit, so the system had to be creatively engineered for a compact, space-efficient design.
LACK OF INTERNAL RESOURCES FOR PACKAGING DESIGN
In addition to equipment needs, the client was developing a new consumer product line and required packaging film and branded bag designs. With no internal marketing or packaging team, they needed a partner who could help them source materials and ensure the packaging met both aesthetic and functional standards.
The solution
SMART USE OF IN-HOUSE EQUIPMENT
SIGMA Integration expedited the project timeline by sourcing key components from its vast in-house inventory. Readily available equipment, such as a lightly used Hayssen Sandiacre bagger, along with a metal detector, a checkweigher, and a rotary accumulation table, were integrated into the new line — delivering reliable performance without the lead times or costs of new machinery.
LOW-PROFILE SYSTEM DESIGN FOR SPACE CONSTRAINTS
To address tight 13-foot floor-to-ceiling space limitations, SIGMA’s engineering team developed a custom low-profile mezzanine that housed the Ishida scale at an accessible height. This solution enabled a compact, vertical product flow, using an indexed incline conveyor to feed the bagger, preserving efficiency without compromising usability or safety.
END-TO-END TURNKEY DELIVERY
From engineering and assembly to integration and installation, SIGMA delivered a fully functional turnkey system. By managing every phase in-house, including testing the system at SIGMA’s facility, the team minimized downtime, streamlined deployment, and ensured the system was production-ready.
FULL-SCOPE PROJECT SUPPORT BEYOND EQUIPMENT
SIGMA’s involvement didn’t stop at the line build. The team helped Harvest Select find a reliable film supplier and connected them with marketing professionals to work with them on bag design and branding. This extra level of service ensured the finished product not only met production goals but also stood out on store shelves.
The RESULTS
SIGMA Integration helped Harvest Select make a seamless leap into the retail market — on time and on budget.
By engineering a custom, space-conscious packaging line and leveraging both new and in-house equipment, SIGMA delivered a fully automated system that met all performance targets without expanding the facility footprint.
The result was more than just a new line — it was a complete solution that more than doubled output, improved weighing accuracy, and positioned Harvest Select for long-term success in the retail space.
PRODUCTION RATE
2 lb bags: 22–26 bags/min
4 lb bags: 14–16 bags/min
EFFICIENCY & ACCURACY
More than 2× output vs. manual process
Integrated scale improved weighing precision
FACILITY FIT
Engineered to operate within 13-ft vertical clearance
Download Our Case Study PDF Here:
Let's Get in Touch
Maximise Production Efficiency
SIGMA Integration engineers design and install turnkey processing and packaging lines tailored to your manufacturing needs.
or Call (812) 303-8383