Case Studies

Tan Y Castell Welshcakes

03/03/2008

Tan Y Castell Welshcakes started life as a cottage industry. When Paul Mear set up his baking enterprise 14 yrs ago, the business had to be slotted rownd his day job as a lecturer in agriculture at Pembroke College.

Tan Y Castell produce is now sold throughout the UK and the company supplies a number of major supermarkets, along with Harrods and Fortnum and Mason.  

Tan Y Castell produce is now sold throughout the UK and the company supplies a number of major supermarkets, along with Harrods and Fortnum and Mason.  

Tan Y Castell is committed to quality, and its welshcakes are made from the finest ingredients, with no added preservatives, colouring or salt

“I think the secret of our success is that we haven’t compromised the authenticity of the original recipe” explained Mr Mear, Proprietor

“It would have made life a lot easier for us had we adjusted the recipe to suit the machinery, instead, we have modified our machinery to suit our product style”

Tan Y Castell welshcakes are still hand baked – only the rolling and cutting aspect of the process is completely mechanised.

“It may be labour intensive, but this is part of the reason why the flavour and texture of our product is exceptional” added Mr Mear.

MAS Wales brough about a dramatic improvement in production – increasing the number of cakes obtained per strip of dough from 600 to 1,000.
This increased production was achieved by changing cutting patterns – a change of technique that also cut down on waste – and ultimately improve profitability by 25%.  As a result of MAS Wales input, significant production line improvements were made.  The least efficient line was decommissioned but kept on site as a back-up in case of an emergency.

With staff co-operation, shift patterns were altered to man the single production line – now set to run for 18 hrs a day.

“MAS helped us to work out an effective shift pattern and better work methods and also provided help with training supervisors in managing these new systems” said Mr Mear

“Running a single line has helped free up space, as there are now fewer people in the plant at any given time.  This has enabled us to hold some stock in reserve which has in turn, improved our ability to fulfil our customers’ requirements.

“We need to produce a set number of cakes each hour in order to maintain profitability” said Mr Mear.  “Since working with MAS Wale, our cakes per hour figures have improved – but without increasing labour hours”

“Thanks to MAS, we have succeeded in increasing production without needing to expand our premises, thus avoiding a costly and disruptive process” explained Mr Mear.