Take one foodie and one manufacturing engineer, add a team of experts in their field, support from conveyor designer and manufacturer, Dyno NZ and the determination and passion to create a great product and you have Button Family Crumpets.
Based in Christchurch the company is the brainchild of Daniel Button and Murray Hammond and the two men have undertaken quite a journey to get to the stage where they are now, testing, with going to market on the near horizon.
“My business partner Daniel Button called me from Saudi where he was working a few years ago and asked for my help in setting up a crumpet factory,” Murray Hammond says. “We learned Honeycomb’s bakeline was up for sale. I looked into it. It was in a container and the building had suffered in the earthquakes. We secured the equipment and started looking for premises – in Sockburn.”
Murray says that because the company was a startup he and Daniel were looking to keep costs down but had to do work to restore their new premises and build up equipment and machinery.
“It’s been a long project. The premises needed to be restored – we repaired the floors and walls to food grade standard. While that was happening we were collecting equipment. The old bakeline – was old machinery with manual stacks. We sourced a high end packaging machine, some conveyors and tables.
“I started talking with Dyno – our vision was to produce a high end quality product and to do that we didn’t want to handle the product. We wanted to automate the process to create the Rolls Royce of crumpets.
“We needed to stack the crumpets – to supply our flow wrapper with pre-stacked crumpets automatically. We figured that we needed a roller conveyor. Dyno were really good at collaborating with me – they understood the solution we were after. They worked with our concept, gave us working drawings to review. We got their expertise and know how on that and once we were happy with the drawings we pressed go for fabrication, assembly and testing.
“When we engaged Dyno we told them our story and they were flexible – they are open to the best way for the customer,” Murray says.
Dyno has supplied four conveyors to Button Family Crumpets. A Crumpet oven discharge conveyor –a stainless steel mesh belt take crumpets directly from oven. A Transfer conveyor, which has a urethene band belt to transfer crumpets through wall into a temperature controlled room to cool crumpets.
A Mini roller accumulating conveyor – slip torque style rollers accumulate crumpets into position and creates crumpet stack. A Mini roller conveyor – that accepts the crumpet stack and transfers it to the flow wrapper. These conveyors were manufactured in stainless steel, food safe and suitable for washdown.
Dyno design, manufacture and supply a comprehensive range of conveyors and conveyor components, ranging from small specialist bearings to full turnkey systems. Their products are tailored from economical standard parts or manufactured to meet a particular requirement from both the tried and proven, to the latest in international technology. Their knowledge and experience makes them very versatile and they have the capabilities to provide the ultimate solution. They prefer to work alongside customers to ensure they achieve the outcome they require, within budget and on time.
So with all the pieces in place the next step for Button Family Crumpets is to get the crumpets rolling out the factory and in to stores throughout New Zealand. “We have the magic back,” Murray says. “We’re getting the crumpets to the repeatable stage. Every day we set up one or two bakes and then we do it again.”