Archives for April 2011

Over the past few years AIS has undergone a complete company restructuring. We have implemented changes in every aspect of our company including customer development and support. From better trained, and more experienced technical support, through smarter ice system installations, we have greatly improved all that we do and our value to the client. ese and many other changes have been a part of our Different, Smarter, Better focus.
We have brought to question everything that we do and how we do it. Our goal is to do things Different, Smarter, and Better within our company, with our clients, and with the building of better ice plants. We understand how tough it is for packaged ice producers surrounded by industry consolidation, increased operating cost, and a difficult economy. ese challenges require changes to survive and to succeed, and our company’s focus has been on exploring and implementing changes to help in our clients’ success. is newsletter focuses on doing things Different, Smarter, and Better. From increasing your production without increasing your electric bill, eliminating labor through complete system automation, to more comprehensive preventative maintenance, and making better merchandiser purchases, AIS wants to help secure your company’s future success. If you have any other solutions you would like to share on how your company is doing things Different, Smarter, and Better, contact me. I would love to hear from you; together, with positive change, we will succeed.

– Doug Carpenter

In the spring Cold Standard there was an article titled e Next Step in Automation. In this article we reviewed how we are building ice plants today that are Different, Smarter, and Better. Today’s Automatic ICE™ Systems™ are more energy efficient, greatly reduce operational labor, and require much less real estate. e catalyst to these modern Automatic ICE™ Systems™ is total system automation. By eliminating almost all operational labor, seasonal around the clock operations can be justified. If a 200-400 pallet a day packaged ice producer can be staffed with only one or two operators, many of the obstacles to ondemand packaged ice production can be overcome.
AIS had the opportunity to develop two systems utilizing total system automation in the spring and early summer of this year. One of these facilities is capable of a daily output of 340 pallets and the other plant 250 pallets of packaged ice. Both systems utilize only two packaging lines, two automatic palletizing machines, fully integrated product and pallet handling components, along with automatic pallet and slip-sheet dispensing, and automated stretch wrapping. An operator is only required to monitor the system and keep it supplied with consumables. Depending on the rate of output, that same operator can remove the finished, palletized and wrapped pallets of packaged ice from the discharge. As a testament to capabilities of these systems, I received a call from one of the system owners who opened his plant early during a high demand period, turned the system on, and in three hours put 41 pallets of ice in the freezer, while answering a few phone calls and having a cup of coffee.
Labor costs continue to rise. Reliable operators are harder to find, and a competitive market place makes rebuilding packaged ice plants a necessity, not an option. Today, the technology exists and AIS has the key to unlocking its potential.

FREQUENTLY WE ARE ASKED BY PACKAGED ICE PRODUCERS HOW MUCH ICE a particular ice maker is capable of producing. Our answer is quite often, “what are your goals”. We don’t answer this way to confuse or to mislead people, but we answer in this way to assure that we make the best recommendation. When determining the capacity of an ice making system there are three major determinants: One, the purity of the water used, two, the amount of refrigeration used, and three, the hardness of the ice that is desired. Whereas packaged ice machines are engineered for average water quality and to efficiently produce the maximum amount of ice, high-capacity split-refrigeration systems can be engineered specifically to match each individual application.
Better, more efficient ice production begins with choosing the right brand ice maker. e Vogt® line of Tube-Ice® Makers is the finest within the industry. ese machines are not only the most efficient ice makers available, but the Tube-Ice line is the longest-lasting, lowest maintenance brand of ice machines made. is trusted brand is the starting point for most packaged ice applications. With these proven low-side, ice makers, AIS builds AIS Ice Manufacturing Systems best suited for each individual project. Using as an example the Vogt P34AL-15 lowside ice maker, this unit may be engineered to produce anywhere from 45 tons to 95 tons of ice production per day. In applications involving poor water quality and/or built for future growth, we may engineer a system to produce only 45 tons of initial daily capacity that requires very low electrical demand. Although the same ice maker attached to a large, house refrigeration system that demands large amounts of ice, without worry to quality or hardness, may approach 100 tons of daily production. Reverse osmosis water treatment can allow for greater capacity systems utilizing a higher horsepower refrigeration system, but the more horsepower, the more electrical cost per ton of ice. Not to mention a much greater water requirement. With this in mind, AIS takes the time to determine each individual client’s needs and develops a plan to best accomplish our client’s goals. We are not merely interested in selling your company equipment; we want to make sure you get the most from your investment. We want to build successful future clients.
In talking with ice producers throughout the county and world-wide, we have found that many have actually decreased their operating efficiency in the effort to squeeze a few more tons of daily production out of their ice makers. In some of these operations we have added additional ice makers to the existing high-side refrigeration system and increased their daily ice making capacity by up to 30 tons without consuming any more electricity. ink about it, 30 more tons of ice without a higher electric bill. Now that is smarter. So it is not necessarily how much ice can an ice maker make, but how much should an ice maker make. At AIS, we thoroughly review your current and future operational goals, and develop a plan for the smartest way to accomplish these goals. If your company is considering adding ice production, give AIS a chance to review your system application. We would enjoy the opportunity to put our experience and expertise to work for you.

TWO YEARS AGO AIS BEGAN PRODUCING PREVENTATIVE Maintenance Manuals at the conclusion of every project. e decision to spend time and energy to produce these manuals came from years of post project frustration. What we were finding was that clients were not abiding by the verbal preventative maintenance (PM) recommendations we stressed nor were they following the manufacturer recommendations outlined in the equipment manuals. Equipment PM was being neglected, and after a few years the equipment was reminding our clients of their neglect at the busiest time of the year. Summertime breakdowns were costing some past project client’s valuable production time and creating untimely service calls and emergency parts shipments. In a seasonal manufacturing business like packaged ice, every hour of summertime production can be essential.
Our post project PM Manuals have been well received and have brought focus to the necessity of regular equipment PM and the stocking of essential spare parts. is change has been positive for both us and our clients. Our clients stay in production during busy times, and we are challenged with fewer service calls and fewer emergency parts shipments.
What about packaged ice producers that don’t have AIS PM and Spare Parts Manuals? Take the time this fall to make your own. Gather together all of your equipment manuals, request new ones, or go online and download new manuals. Isolate the PM sections and convert this information into a similar format for each individual equipment component. en assemble this information into a binder and organize it by product or time interval (daily, weekly, monthly, and annual, etc). For custom equipment without manuals, discuss recommended procedures and past problems with your maintenance staff and create a list. Once you have assembled your PM manual, follow it without fail. You will find that your manufacturing operation will run much smoother and with significantly less summertime headaches.

Our clients count on us to make the right equipment recommendations. Therefore, at AIS we are careful to research the options available and partner with only the best equipment manufacturers. For over 25 years AIS has exclusively represented the Leer merchandiser product lines. Not only does Leer build the finest, most reliable ice merchandisers, but their products are constantly improving. Like AIS, Leer continually works to improve their product offering with enhancements and product improvements. ey not only want to build the best ice merchandising units today, they want to continue to build the finest units tomorrow.
As a Leer distributor, you may believe we are biased. Don’t just take our word for it, ask around. Nearly all packaged ice manufacturers will agree that Leer is the finest brand of ice merchandiser. What doesn’t make sense is that some ice companies knowingly purchase merchandiser brands they believe to be inferior to the Leer brand. The motivation to these purchases seemingly is price. For a one to two hundred dollar per unit savings, some ice companies take a gamble with other brands. For what commonly equates to around a 5% cheaper merchandiser, some make a major compromise. I agree, one or two hundred dollars seems like a lot of money. It means a night out on the town; as long as you don’t have too much fun. And what if you buy a truckload, yes that really can add up. Although, what about the other side of the balance sheet. How much does this decision cost your company? You need to factor in additional maintenance calls, product loss, unhappy customers, and product replacement. Almost everyone will agree, Leer brand merchandisers are more reliable. What does a service call really cost your company? For most, the cost of just one typical merchandiser service call can consume the entire initial savings. Factor into this the removal of melted product and the routing of replacement ice, and suddenly your initial savings begins to cost your company money. Not to mention the dangers of an unhappy customer during a busy time of the year with competition calling on them. And finally, don’t forget about replacement cost. Inferior merchandisers don’t last as long. I hope I am making myself clear. It is not about saving a few dollars up front, it is about making the right investment. Quality ice merchandisers are a critical investment, and are your company’s direct link to both the retailer and the consumer. Good looking, quality, reliable ice merchandisers make you money; don’t compromise your investment.

The True Cost of Merchandisers

Our clients count on us to make the right equipment recommendations. Therefore, at AIS we are careful to research the options available and partner with only the best equipment manufacturers. For over 25 years AIS has exclusively represented the Leer merchandiser product lines. Not only does Leer build the finest, most reliable ice merchandisers, but their products are constantly improving.

Comprehensive Preventative Maintenance

TWO YEARS AGO AIS BEGAN PRODUCING PREVENTATIVE Maintenance Manuals at the conclusion of every project. e decision to spend time and energy to produce these manuals came from years of post project frustration. What we were finding was that clients were not abiding by the verbal preventative maintenance (PM) recommendations we stressed nor were they following the manufacturer recommendations outlined in the equipment manuals.

Smarter, More Efficient Ice Production

FREQUENTLY WE ARE ASKED BY PACKAGED ICE PRODUCERS HOW MUCH ICE a particular ice maker is capable of producing. Our answer is quite often, “what are your goals”. We don’t answer this way to confuse or to mislead people, but we answer in this way to assure that we make the best recommendation. When determining the capacity of an ice making system there are three major determinants:

Total System Automation

In the spring Cold Standard there was an article titled e Next Step in Automation. In this article we reviewed how we are building ice plants today that are Different, Smarter, and Better. Today’s Automatic ICE™ Systems™ are more energy efficient, greatly reduce operational labor, and require much less real estate. e catalyst to these modern Automatic ICE™ Systems™ is total system automation.

Different. Smarter. Better.

Over the past few years AIS has undergone a complete company restructuring. We have implemented changes in every aspect of our company including customer development and support. From better trained, and more experienced technical support, through smarter ice system installations, we have greatly improved all that we do and our value to the client.