A niche in the New Zealand potato chip market for locally grown, locally made and locally owned product has enabled a South Island potato farmer to produce his own potato chips, in his own factory, from his own potatoes.
Heartland Potato Chips was formed when the Bowan family was given the opportunity to purchase the old Bluebird Washdyke factory based in Tiramu in February 2009. The family had a potato farm in South Canterbury, in the heart of New Zealand’s South Island, and had once been a supplier to a major snack food company in New Zealand.
Knowing that quality control always starts at the farm, this bold and enterprising decision to go into potato chip manufacturing would change their life. A niche market in the New Zealand potato chip industry for locally grown, locally made and locally owned product was born.
Timaru potatoes, well known for their great flavour and low sugar content, make the perfect potato chip and, because of this, Heartland Potato Chips wanted only the best packaging and product handling equipment to complement and add value to their raw product.
With Heat and Control’s reputation in New Zealand for manufacturing and sourcing only high-quality equipment, they were approached and able to listen to the Bowans’ needs and concerns, and found a way to be flexible in their approach to provide Heartland with the packaging equipment and product handling equipment they needed to achieve their goals.
Heartland Potato Chips were after specific equipment to complete their line. Scott Burrows from Heat and Control explained, “FastBack conveyors were an ideal choice for transporting such a delicate product as potato chips. The horizontal motion of the conveyor reduces breakages of delicate products, and also minimises seasoning loss. Bill Cockburn, Product Manager of Heartland Potato Chips, and with over 37 years in the food industry, had previous experience with Ishida multihead weighers, so this equipment had already proven its capability for accuracy, as well as longevity and reliability.”
Burrows continues, “Bill’s previous experience leant him towards the Ishida equipment, unfortunately a complete Ishida packaging line was not possible. The line speed/packaging speed required to ‘pull’ the processing supply volume did not warrant a high-speed Ishida VFFS solution. Although when the time comes, they may choose an Ishida Atlas bagmaker which has product stripping capabilities, as the specific gravity (solids) can change through the seasons and therefore the bulk density when packed.”
With the experience of the sales, engineering and project management team, Heat and Control was able to provide Heartland with an Ishida computer checkweigher, Heat and Control FastBack conveyor system and CEIA metal detector, as well as Matrix packaging machinery from the USA to complete the 300 kg/h potato chip line. The result, success!
“Extreme care was taken when purchasing our equipment. Conditioning units, along with a modern fryer, were purchased overseas, but when it came to our end-of-line equipment, we looked to Heat and Control to supply us the best quality and reliability to complement our line,” said Bill Cockburn.
With delivery of the equipment just one day prior to the New Zealand earthquake, and with the practical attitude of the South Island people, the Heartland Potato Chips project installation team got on with installation of the equipment into their newly refurbished factory. A sheer indication of their dedication and pride, and why they are named Heartland Potato Chips. So with a passion for a challenge and with over 40 years’ experience, Ray Bowan, farmer/owner of Fallgate Farms and now CEO/owner of the new Heartland Potato Chip Company, finally got a chance to fulfil a lifelong dream — to produce his own potato chips, in his own factory, from his own potatoes.