Majans’ partnership with TNA solutions delivers 140% throughput increase in 12 months with the tna ropac® 5

Majans has taken significant strides in automating its operations by leveraging the advanced tna ropac® 5 technology from TNA solutions.

Operating at a capacity of 200 bags per minute and featuring a bag conditioner, case packer, case erector, and checkweigher, the tna ropac® 5 is the fastest case packing system on the market with the smallest footprint. Since its deployment, Majans has seen an impressive 140% increase in throughput and a 15% increase in uptime within just 12 months. 

Established in 1984, Majans produces over 2 million cases of snacks annually across 53 products. The company needed a trusted partner to navigate a challenging labor market and volatile supply chains while aiming to enhance throughput, reliability, and operational uptime.

With prior positive experience using TNA solutions at Mars, Manufacturing Manager Andrew McManus was reassured when Majans' owner, Kam Raniga, selected TNA to help future-proof their operations.

Challenge 1: Securing a Partner for Long-Term Growth

As Majans expanded in the snacks sector, automation became essential to keep pace with growing demand. Kam Raniga developed a strong relationship with TNA founders Nadia and Alf Taylor, leading to discussions about enhancing productivity at Majans' Sumner Park site in Brisbane.

In 2019, Majans replaced five older systems from an alternate supplier with two tna robag® baggers. This upgrade significantly increased production efficiency, with multipack product output rising from 1,200 cartons per week (produced in 10 hours by 13 people) to 14,000 cartons per week (produced in under 17 hours by 6 people), reducing the labour cost per kilo from USD 2 to under USD 1. Recalling his experience with TNA baggers at Mars, Andrew McManus noted their reliability and longevity.

Andrew McManus:

"In my previous company we had two robags that ran for 40 years. Their incredibly consistent performance gave me great confidence that when we select a TNA piece of equipment, you know they're going to last."

Andrew McManus, Manufacturing and Supply Chain Manager at Majans

Challenge 2: Progressing from Manual to Automated Case Packing

Majans' continued growth led to the need for further automation, particularly in its case-packing operations. With the labor market tightening, Andrew McManus aimed to retain existing staff while increasing efficiency.

Having had a positive experience with TNA's automation of the bagging process, he approached TNA for the case-packing solution. The tna ropac® 5 was selected for its high capacity and small footprint, fitting seamlessly into Majans' space-constrained facility. 

Since its introduction in February 2023, the tna ropac® 5 has boosted throughput by 140% and increased uptime by 15%. The system can also accommodate Majans' plans to switch to paper-based packaging in 2024, supporting the company’s sustainability goals without affecting production speeds.

Andrew McManus highlighted the transformative impact of TNA solutions: Andrew McManus:

"Introducing tna ropac® 5 systems has enabled us to improve operational efficiency, redistribute manpower, and future-proof our operations as we look to continue our growth path."

The transformation from Manual Mixing to Automated Agility

Five years ago, Majans operated with 28-35 people per shift for bagging, mixing, and case packing. Today, with TNA's help, the same factory runs with just 10-11 people per shift, achieving outputs up to 6.9 times greater than before the automation process began.

This shift has turned casual jobs into stable, full-time employment, and staff have been upskilled to manage more advanced machinery. Reducing manual labor has significantly decreased the risk of injury and improved overall safety. 

Thiago Roriz, Chief Operating Officer at TNA Solutions, expressed gratitude for the partnership with Majans, emphasizing TNA's commitment to innovation and delivering substantial business value.

Thiago Roriz:

"We are extremely grateful to Majans for choosing us as their trusted partner, to support their goals as they focus on their expansion strategy."

For those interested in learning more about TNA's snack solutions, the company will be present at the SNACKEX show in Stockholm, Sweden, on June 19-20.