Bio Productions is a multi-award-winning manufacturer of environmentally conscious cleaning products for professional, janitorial, and industrial use. The COVID-19 pandemic highlighted the critical importance of cleaning and sanitation, driving unprecedented global demand for Bio Productions’ products.
Operations Manager Chris Freeman and Production Planner Tom Karn discuss the company’s exponential growth and ongoing success while trialling a new System F-1800 R&D filling machine from long-standing partner Adelphi Masterfil.
Industry Innovators in Sustainable Cleaning Products
Bio Productions has been an industry innovator since 1986, when it developed the world’s first user-friendly enzyme-based drain unblocker for the agricultural sector.
Their expansive facilities now house a fleet of Adelphi Masterfil filling machines, renowned for industry-leading precision. These machines deliver exceptional accuracy of ±0.1% on the servo filler or ±0.2% on the standard model, significantly reducing costly product waste.
Faster filling performance - with a pallet filled, capped, and ready in as little as 10 minutes - increases revenue potential. Meanwhile, clean-in-place (CIP) functionality drastically reduces changeover times between products, giving Bio Productions a clear competitive advantage.
Robust and Reliable Filling Technology
Cutting-edge products require cutting-edge technology, particularly when filling challenging acidic products such as Bio Productions’ limescale remover.
The System F-1800 R&D filling machine features 316L grade stainless steel wetted parts, containing an additional 2% molybdenum to provide superior corrosion resistance.
Chris also highlights the longevity of Bio Productions’ oldest Masterfil filling machine, which has been in operation for over 30 years, saying:
“It’s filled a ridiculous amount of products over the years!”
Increased Efficiency and Greater ROI
Instant recipe recall functionality on the System F-1800 significantly reduces set-up and changeover times when switching between products and container sizes. The machine’s rise-while-fill capability reduces foaming, helping maintain fill accuracy and consistency.
Together, these features have increased Bio Productions’ achievable daily throughput to as much as 8,000 litres per day.
Adelphi Masterfil’s remote support service is also highly valued. Chris explains:
“There were some teething issues after installation, as expected with a development machine, but there’s been no problems since. Whenever there is an issue we can pick up the phone and someone will quickly assist or come and take a look.”
Tom also praises the professionalism of Adelphi Masterfil’s engineering team, particularly Paul Rickman, who installed the R&D machine:
“He’s a good engineer and very personable — he got along with all the members of our team very well,” with Chris adding, “He’s a really good egg!”
Green Credentials and a Shared Commitment to Sustainability
Bio Productions and Adelphi Masterfil share a strong commitment to sustainability, each leading environmental initiatives within their respective industries.
Bio Productions has received multiple Green Apple Awards for Environmental Best Practice. Adelphi Masterfil’s multi-award-winning eco-friendly production facility features solar panels, rainwater harvesting, air-source heat pumps, and evaporative cooling systems.
“Tried, Tested, Trusted” – Quality Assurance Guaranteed
Quality is paramount at Bio Productions, supported by a four-person quality checking system to ensure product integrity at every stage.
Both Bio Productions and Adelphi Masterfil are ISO 9001 certified, independently verifying that the highest procedural and quality standards are met.
Adelphi Masterfil also follows a comprehensive testing programme for every machine, including:
- In-build checks
- Dry testing
- Wet testing
- Pre-FAT testing
- Factory Acceptance Testing (FAT)
These measures ensure machine reliability and maximise production security for customers.
The System F-1800 in Numbers
- Productivity increased by 20% within one week of installation
- Average output of 10 pallets per day, with capacity for up to 18 pallets
- A pallet filled, capped, and packed in just 10 minutes
- Filling throughput reaches 8,000 litres per day
- CIP enables product changeover in 10 minutes, compared to up to an hour on older machines
Customer Recommendation
“Would I recommend Adelphi Masterfil to another company in the industry? If I wanted to make a rod for my own back! But seriously, I wouldn’t hesitate to recommend you.”
— Chris Freeman, Operations Manager
