How Daregal Improved Production Flexibility and Reduced Changeover Time to One Minute Through Process Optimization
Learn how Daregal solved production inefficiencies and enabled multi-product processing on a single line
“By solving a complex drying challenge, we enabled Daregal to switch between different product formats in just one minute without compromising efficiency.”
About Daregal and their role in large-scale food production
Daregal is a leading international producer of culinary herbs, supplying food manufacturers across global markets. The company operates in high-volume production environments where consistency, efficiency, and flexibility are critical.
Why processing multiple product types on one production line created operational challenges
Daregal needed to process very different product formats on the same production line.
This included:
Large bulk bags up to 400mm by 560mm by 60mm
Bottles ranging from 146mm to 290mm in height
Each format required a different drying approach, making it difficult to maintain a consistent and efficient process.
How limited production flexibility was affecting efficiency and scalability
Without a flexible solution, Daregal faced several challenges.
Separate production lines would be required for different products
Additional investment and floor space would be needed
Operational complexity would increase
Production planning would become less flexible
This made it harder to scale operations while maintaining efficiency.
How Optimus Instruments optimized the process and implemented the right drying solution
To solve this, Daregal partnered with Optimus Instruments.
The goal was not just to install equipment, but to improve how the process handled different product formats.
Optimus analyzed the production setup and identified the need for a flexible drying approach. Based on this, a custom SolvAir 3 in 1 Air Knife system was selected and integrated into the line.
The system included:
A 5.5kW Paxton blower
Strategically positioned stainless steel air knives
A wire mesh conveyor
Adjustable components to accommodate different product sizes
The solution was designed to fit seamlessly within the existing production environment.
How reducing changeover time to one minute improved production efficiency
One of the key improvements was the ability to switch between product formats in just one minute.
Operators could move from drying bulk bags to bottles quickly, without long downtime or complex adjustments
This made it possible to run multiple products on a single line while maintaining performance and consistency.
What results Daregal achieved after implementing the optimized process
After implementing the solution, Daregal achieved clear improvements.
One production line could handle multiple product formats
Changeover time was reduced to one minute
Production flexibility increased significantly
No additional production lines were required
The process became more efficient, predictable, and easier to scale.
Why improving process flexibility directly impacts production performance
The impact went beyond operational improvements.
By increasing flexibility, Daregal was able to:
Respond faster to changing production needs
Avoid investment in additional lines and infrastructure
Maintain consistent output across different product types
This created a more efficient and future-ready production setup.
Final thoughts on improving production efficiency through better process control
This case shows that improving performance is not always about adding more equipment.
In many cases, it comes down to understanding the process and selecting the right solution to control it effectively.
Looking to improve production flexibility and reduce inefficiencies in your process
If you are looking to run multiple product formats on a single line without compromising efficiency, Optimus Instruments helps you analyze your process and implement the right solutions to improve performance.