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Johan Bülow began his licorice adventure on Bornholm in 2007 with a transparent vision of bringing gourmet licorice to the whole world. Today, the candy manufacturer Lakrids by Bülow supplies gourmets, retailers, and its own stores globally from its high-tech factory in Hvidovre. Due to demand, production runs around the clock, and this naturally places high demands on machine uptime, as unforeseen downtime quickly impacts the bottom line.
Working with a very hot and extremely sticky substance like licorice requires high-quality process equipment. The company’s quality department – particularly in light of FSSC certification – imposes strict, non-negotiable requirements that all equipment in direct contact with food must be made of stainless steel and, of course, food-grade certified. To ensure the same high-quality product in every batch, operators work according to fixed standards and procedures. Food safety is continuously monitored with metal detectors on the production lines, while any defective products are sorted out for use as animal feed.
Central to candy production is the factory’s licorice cooker, where the raw materials are mixed and transformed into the finished licorice paste. For a long time, a traditional sealing solution using packing string caused major mechanical problems and frequent stoppages on this critical machine. The repeated frustrations eventually led Lakrids by Bülow to reach out to Alfotech. The close collaboration resulted in a custom-designed cartridge sealing solution that has transformed one of the factory’s biggest bottlenecks into a stable plug-and-play success.
The packing string that slowed down licorice production
In his role as an Operating Technician at Lakrids by Bülow, Mads Chabert manages a busy daily routine involving both preventive and emergency machine maintenance. He knows better than anyone about the past, when the licorice cooker’s seal was a source of daily irritation because the traditional packing string simply deteriorated far too quickly and simultaneously shifted out of position during daily operation.
When the packing string failed, the necessary pressure in the chamber dropped, preventing the heavy licorice mixture from being pushed out. As a result, the entire production line came to a halt. Mads and his colleagues had to retighten the packing string daily and replace it entirely every three weeks. Furthermore, the packing string’s heavy pressure wore down the axle, so the axle had to be replaced three times over the years.
Quick 3D scanning and flawless custom flange
After several critical production stoppages, Mads Chabert sought advice from Alfotech. Following a quick site visit to the factory and a thorough assessment, the choice fell on a long-lasting custom solution: the popular and robust LDC40 double cartridge seal combined with a custom flange and an external cooling system.
To make room for the new installation, the licorice cooker’s end flange had to be modified with a larger inner diameter and four bolt holes instead of three. Since production could not tolerate long downtime, Mads quickly had the original flange 3D-scanned at a local engineering firm. Based on the CAD drawings, the new custom flange was then manufactured. Just two weeks after the order was placed, Mads and his colleagues were able to say goodbye to the packing string and put the new, modern custom solution from Alfotech into use.
Freed-up man-hours and stable operational reliability
The new installation has significantly changed daily operations. In production, they now save up to 72 man-hours per year on scheduled maintenance alone. The seal is now 100% plug-and-play, ongoing expenses for spare parts have dropped to zero, and the unit’s service life has improved significantly.
The biggest benefit, however, is the uninterrupted operational reliability. Previously, the licorice would occasionally spill out of the licorice cooker, resulting in multiple breakdowns. But today, the machine maintains a stable pressure, and the plant technicians can instead focus their resources on the other production lines.
A strong recommendation for colleagues in the process industry
Based on past challenges with the licorice cooker, Mads and his colleagues have gathered valuable experience that other companies in the process industry can greatly benefit from. His primary advice to other technicians is to ensure they have a completely realistic and data-driven understanding of how long a traditional packing string can actually last on that specific machine.
At Lakrids by Bülow, measurements showed that the seal could run for a maximum of three weeks before preventive maintenance became critical to keeping the production line running. Mads therefore recommends that others facing similar challenges look into a permanent solution with a cartridge seal much earlier in the process, rather than wasting valuable production time and money on temporary, alternative standard solutions.
A collaborative and solution-oriented partnership
The process has cemented confidence in Alfotech as a competent partner that provides prompt follow-up and personal contact. Mads specifically uses the words “reliable,” “responsive,” and “understanding” because the company offers genuine advice rather than simply selling off-the-shelf standard components.
This close, customer-centric partnership is directly reflected in Alfotech’s strong commitment and willingness to understand the specific challenges of production. Mads expresses great satisfaction with their ability to put themselves in the customer’s shoes and respond quickly:
You really roll up your sleeves and tackle the task head-on, and your sales consultant has actually been out here to visit us twice to see things from our perspective and assess the situation. At the same time, you’re incredibly good at following up and getting back to us quickly with answers.
Mads Chabert
Operating Technician, Lakrids by Bülow
About Lakrids by Bülow
Lakrids by Bülow is an international confectionery brand offering unique products based on innovative combinations of licorice and chocolate. The company was founded on Bornholm in July 2007. With stores in Denmark, Germany, the United Kingdom, Sweden, Norway, Finland, and the United Arab Emirates, the company’s products are sold through nearly 2,000 retailers in 35 countries.
Lakrids by Bülow, which in 2019 became the first confectionery company in the world to switch to jars made from 100% recycled plastic, has recently achieved B Corp certification, underscoring the company’s commitment to high social and environmental standards.
About Alfotech
Alfotech is a Danish-owned company founded in 1984. We represent several international suppliers of quality products and solutions that naturally meet the strict requirements of the process industry.
Our customers are from the food, pharmaceutical, and chemical industries. We sell, develop, and manufacture many of the components used in our solutions. The knowledge gained from 40 years of developing and selling spare parts and technical solutions gives us great expertise in finding the right solution for your business.