Case history
Coghlan’s
Bakery
Coghlan’s is one of Ireland’s most innovative and highest-quality product Industrial Bakers.
We present one of our main case history made at the Coghlan’s Bakery plant, in Ireland, located in Naas, near Dublin.The company has installed several machines, from the fabric silos for storing flour, which is fully integrated along with the innovative, patented Agriflex dough cooling system. Once cooled, the raw materials reach the dosing points on the kneading machines. Everything is fully automated, thanks to our systems, with a significant reduction in labour costs, cooling aids such as ice, and at least 70000 boxes and packaging material, with a positive impact on costs and the environment never seen before.
Interview
We asked the management a few questions about the business needs, the solutions adopted and the future horizons that our storage, handling and automation solutions open up for them.
What is the history of Coughlan’s, what are the main products you make, and with which production cycle?
Started by Yolanda Coghlan. and Brendan Coghlan in 1989 with four people today we have 180 people. We produce soft bread products, mainly brioche burger, buns and hot dogs. We also make a range of rolls and baps.
What are the main distribution channels for Coghlan’s products? How does the company position itself in relation to the competition?
Own brand retail to main multiples in Ireland.
What was the main need/problem to be met that prompted you to adopt Agriflex solutions?
We needed to improve our environmental impact.
What advantages have you experienced in using Agriflex storage and dosing solutions in your product production?
We experienced significant savings in the labour cost of handling individual boxes and bags, savings in traceability paperwork costs, and the elimination of 70,000 bags and boxes and the handling, disposal and environmental costs.
How has your production efficiency improved thanks to our cooling system?
We would use in summer approx. 10,000 kg of ice per week. With the constant delivery of flour to our mixers at 12 degrees C we only need to manage our water temperature. We have eliminated the need to use ice.
We have eliminated the cost of producing, handling, and cleaning associated with ice.We experienced an immediate improvement in the quality and consistency of our doughs. The workload for our personel at the mixing stations has been reduced significantly. Giving us an increase in hourly throughput
How does the synergy created with Agriflex adapt to new market trends and technological innovation?
Coghlan’s bakery has always positioned innovation and new product development as key components of its overall strategy. Partnering with Agriflex for our material handling gives us complete confidence that we can maintain a competitive advantage in this area. Agriflex’s modular systems means we can respond to emerging trends with high levels of efficiency and in a timely manner whilst reducing our environmental impact.
Did your collaboration with Agriflex help you achieve the goals necessary to realize your long-term vision for the Coughlans company?
Coghlan’s Bakery aims to be the leading supplier of brioches burgers, buns, rolls, soft breads and pastries on the island of Ireland and beyond. Producing a superior quality product at large volumes is extremely challenging. Agriflex material handling systems and flour cooling have allowed Coghlans to not only improve the overall quality of the products produced, but has helped relaise significant cost savings and reduced out environmental impact, thereby making a vital contribution towards us achieving our goals.
We would like to thank Coghlan’s for the fruitful collaboration.
Coghlan’s Bakery – Unit 10, Alder Road – Tougher’s Business Park – Newhall, Naas, Co. Kildare | T +353 (0)45 408127 | F +353 (0)45 408129
E-mail:enquiries@coghlansbakery.ie
