interpack 2014 – Bosch Unveils Record-Breaking Flexible Biscuit Packaging System
The first system capable of pack style changeovers from slug to pile packs and corresponding case formats in less than three minutes was presented with a live demonstration event at interpack in Düsseldorf this May 8-14.
Bosch Packaging Technology introduced its innovative biscuit packaging line, with live presentations throughout the show. It is the first of its kind capable of fast slug to pile changeovers, with the same feeding components, which was accomplished during the “test-drive” in little over two minutes.
By comparison, a traditional machine would take over 5-7 minutes for this procedure. Designed for maximum flexibility, the line also features the fastest product count changes currently available on the market, as showed on the timed demonstration.
The equipment is the result of two years of research and development, the first part consisting of extensive interviews with processors to learn specific requirements to be met, explained Daniel Bossel, product manager with Bosch Packaging Systems, Packaging Technology – business unit: confectionery and food, for World Bakers.
Enabling biscuit manufacturers to meet different global market requirements, the system is capable of producing multiple packaging variations, from smaller on-the-go packages to larger family packs. From distribution through primary to secondary packaging, the line is designed as a single Seamless System for maximized overall equipment effectiveness (OEE).
“With consumer needs constantly changing, biscuit manufacturers need a single packaging system designed for high flexibility from primary through end-of-line packaging. As the first complete system capable of producing slug and pile packs on the same line, it is truly two-in-one and allows manufacturers to meet current and future market needs. It’s a best-in-class packaging solution that will take manufacturers to the peak of productivity,” said Daniel Bossel.
Primary and Secondary Packaging Flexibility
The biscuit packaging line features state-of-the-art product handling technology, horizontal flow wrapping and secondary packaging equipment.
By using the same feeding components, fully reproducible changeovers between both pile and slug packs can be completed in less than three minutes without changing parts. In addition, count changes, for example, from 14 to 8 biscuits per slug or from two-by-two to two-by-four piles, can be realised in less than one minute. This allows manufacturers to quickly run special promotions with maximum uptime.
The line is also capable of handling different biscuit types and shapes. By achieving high productivity from the short changeover times, the line offers fast return on investment.
Complementing primary packaging, the biscuit line is designed for versatile case packing, which can be adjusted quickly and easily to the required format and product configuration with vertical start-up. The case packer is able to run at high feeding rate and products can be supplied flat or on edge. Products can be packaged into cases with retail-ready functionality.
Smaller Footprint
From distribution to secondary packaging, the entire line has been holistically designed as one seamless system. To facilitate high OEE, the speed of all line components is balanced to minimize downtime and optimize production flow. It is designed with the operator in mind, with the same look and feel across the entire line, including one human machine interface (HMI) and standard operating procedures.
As one system capable of producing both pile and slug packs, the entire biscuit packaging line occupies a smaller footprint than two separate conventional machines for both formats.
Additionally, the biscuit line helps protect product integrity. The innovative double infeed balances product flow and facilitates gentle guiding to the high speed flow wrapper featuring new amplified heat seal technology. This new sealing process runs at film speeds up to 80 meters per minute for slug and pile packs – nearly double the film speed of existing technology, the company announced.
Hygiene
The biscuit line offers high visibility and accessibility for areas requiring sanitation, as well as belts that are simple to clean and replace. Gentle product handling technology decreases product breakage, waste and clean up, and the system also features three-dimensional product inspection technology to reject broken biscuits, which prevents crumbs from accumulating throughout the system.