AN organic veg box company has reportedly doubled its packaging capacity and transitioned to fully compostable paper since installing two new GIC vertical form fill and seal packaging machines a year ago.
Riverford, which delivers around 70,000 boxes of fresh produce each week, installed the new machines at Wash Farm in Devon in March 2025.
The GIC4100 VFFS machines replaced two machines that used air and suction cups to form bags that held up to 2.5kg of potatoes.
“Our throughput target is 25 bags per minute,” explained operations manager Dave Gillon. “With the old machines, we were lucky if we were getting ten bags a minute from one machine. So, that’s 20 bags a minute with two machines, but failure rates brought that down to around 15 bags a minute. When you’re trying to do 110,000 bags a week, that’s quite a challenge!
“We had a GIC VFB4 bagging machine installed at our main site about five years ago, which packs salad and leaf crops such as spinach, mixed salad leaves, rocket and wild garlic. Initially, we were forming the bags from standard plastic, but since 2021, we’ve reconfigured the machine to handle home-compostable materials, as Riverford no longer uses plastic on its fruit and veg.
“We worked very closely with GIC on that transition, and it was the strength of the working relationship that we established during that process, and the fact that the VFB4 is such a reliable workhorse, that led us back to them in early 2025 when we decided to upgrade.”
GIC revealed that it worked closely with Riverford to ensure the new machines could work with both the company’s additive-free paper and its scatter print, allowing bag size and capacity to be altered without changing the packaging material.
The GIC4100 is an intermittent-motion machine capable of handling up to 75 packs per minute across a range of pack formats, with widths up to 400mm.
“At the moment, the GIC4100 is delivering 35 bags a minute, which is more than double the output we typically achieved with the previous two machines combined,” Dave added. “Equally important to us is the fact that the paper we can now use is 100% paper. There are no additives or plastics in there, and the machine seals it reliably every time.”
As well as being quicker, Riverford has also reduced the amount of packaging it uses. “Before the GIC machine went in, we needed to store 56 pallets of paper to produce 50,000 bags,” Dave said. “The new approach means we only require 12 pallets to produce the same amount of bags. So, the change has been a space saver, and we are now much leaner in terms of the amount of paper we need on-site.”
Another aspect of the GIC4100 is its inline printer, which means Riverford do not have to pre-print labels.
Following the move to the GIC4100 at Wash Farm, Riverford replicated the installation at its Peterborough site in June 2025. Initially, the GIC4100 packed potatoes, but today it also handles Brussels sprouts and sweet mixed peppers.
“Again, the performance of the GIC machine has been impressive,” Dave continued. “Recently, the team packed 120,000 packs in five days and didn’t go over an eight-hour day. Having the same machine at both Peterborough and Wash Farm has also made staff training and maintenance very easy, and of course, GIC’s team has helped us in those areas too.”
