Jonika, LLC
The fourth generation is now active within the company. Joël Nieuwenhuijse has been with the company for over three years and, following in the footsteps of his father Jaap, focuses on production and the machinery. Jaap’s business partner José handles exports, together with his son Matthias. “You get to observe all kinds of tasks, but I came here primarily to manage production,” says Joël.
That production requires a process that remains flexible, reliable, and easy to manage. That is why Jonika upgraded its automated crate logistics system with a new VHM Fully Automatic Square.
The ambition
Jonika wants to be able to supply its products year-round. Dutch onions have a long shelf life and are shipped from Oostdijk to markets all over the world, with West Africa being one of the most important markets. At the same time, every market has different requirements. That’s why Jonika offers both small and large packages: from 500-gram packages to 25-kilogram bags.
“We’ve made a conscious decision to be flexible,” says Joël. “That allows us to sell onions year-round.” That same flexibility is also needed in processing. In recent years, Jonika has invested heavily in its machinery, including optical sorting machines and packaging lines. The crate logistics system therefore had to be able to keep pace with that development.
The challenge
The partnership with VHM Machinery began in 2020. At that time, Jonika commissioned an automated line for filling and emptying boxes. This consolidated tasks that had previously been performed by two forklift drivers: transporting boxes to the line and unloading trucks that brought onions from the fields. “VHM automated that into a single line. The boxes that are emptied are also filled on the same line. As a result, we can get more work done with just one forklift driver.”
Sorting capacity grew rapidly thanks to the new machines. As a result, the volume of incoming and processed material also increased. Moreover, the first line was one of the earliest models of its kind and experienced frequent malfunctions, particularly with the entry safety system. “On a busy day, you really want as few malfunctions as possible. Otherwise, the entire process grinds to a halt.”
Together with VHM, Jonika investigated whether parts of the existing system could be replaced. They worked with VHM to determine the best solution. The existing line will be repurposed elsewhere, as a complete overhaul proved to be the best course of action.
“The forklift driver never has to wait and is never too late to unload the boxes.”
About Jonika BV
Jonika BV is a family-owned business based in Oostdijk, Zeeland, specializing in onion sorting and packing. The company was founded in 1953 and has been located at its current site since 1962. With 25 to 30 employees, Jonika exports onions to six continents. About 80 percent of the processing involves yellow onions; the company also processes red onions, shallots, and pink onions, among other varieties.
The solution
The new VHM Fully Automatic Square combines the stacking, unstacking, emptying, and filling of boxes into a single automated line. Additional box portals with cross tables and chain conveyors have been installed for all three stackers. This allows boxes to be pre-positioned or removed without the forklift driver having to wait for the next step in the line. This creates a buffer before the next process step.
“In the past, the forklift driver sometimes had to wait for a box to be moved, stacked, or destacked,” says Joël. “Now he can line them up in advance or remove them as needed. He never has to wait, and he’s never too late to take them out.”
The technology in the line has also been updated. The electric Fully Automatic EvenFlowTipr ensures a constant product flow. The hopper filler can handle a higher volume and is better equipped for processing wetter product. In addition, the sensors and entry protection have been improved. The entry safety system now operates reliably, ensuring safety without causing the machine to shut down unnecessarily. “The driver no longer has to keep getting off his forklift to reset the machine.”
The Result
The new line provides greater capacity, fewer breakdowns, and, above all, greater peace of mind. The forklift driver can focus on his work while the system buffers the boxes and keeps the process running. “One person can now get a lot more work done,” says Joël.
That’s important on both sides of the line. Trucks carrying onions from the fields need to be unloaded quickly so that the transporters can continue on their way. At the same time, the sorting line needs a steady supply to keep the packaging machines turning all day. “If one part stops, everything basically grinds to a halt. Now, the process keeps moving much more smoothly.”
The replacement took place in about a week and a half, just before the season began. Jonika mainly uses the system for about four months a year, during the period when onions are harvested from the fields and initially dried. The rest of the year, the onions arrive already dry, and processing is handled through other channels. “This machine was an important step in preventing the receiving and processing operations from becoming a bottleneck.”
The partnership with VHM also plays an important role in this. Joël is in frequent contact with service technician Ricardo, who is very familiar with the machine and Jonika’s operations. In the event of a malfunction, the service department can monitor the situation remotely. “The lines of communication are short. VHM knows our production line and understands how we turn. And in the event of an emergency breakdown, the service team can immediately monitor the situation. It just works great.”
