New Syntegon Discharge Station DCS for Cookies and Crackers

Syntegon is launching the Distribution Continuous Slide (DCS), a new highly flexible discharge station for round cookies, crackers and biscuits. The modular discharge system consists of one or more stations arranged one behind the other. These are equipped with belt slides for particularly gentle handling, minimizing mechanical stress and thus reducing product breakage and loss. Providing optimum pack style flexibility, the Syntegon DCS distributes cookies onto belt legs for packing them flat or on-edge into pile, slug or tray packs. The system’s guard-free design provides operators with unrestricted process visibility, safe accessibility and easy cleaning.

Cookies, biscuits and crackers are taken from the cooling conveyor and are continuously distributed to the leg belts. They are neither pushed nor dropped but slide over the belts and are thereby protected from any mechanical stress. This reduces product loss significantly and leads to efficiency gains, especially when handling particularly sensitive products.

The higher the speed of the belt slide, the more cookies are transferred to downstream leg belts by the DCS. On the individual legs, a further belt slide, arranges the straight product stream into an S-shape. This arrangement ensures the cookies’ and crackers’ are evenly distributed across the entire width of the belt, preventing them from wedging or overlapping. A homogeneous product stream is created, ensuring a constant feed to the packaging machine.

Thanks to its gentle handling, the Syntegon DCS works particularly efficiently and ensures high output and product quality. The system is equipped to handle even briefly fluctuating production volumes intelligently, triggered for example by the failure of a packaging leg. “Individual discharge stations can run at full speed to avoid production loss”, explains Daniel Bossel, Global Product Manager at Syntegon. “If the product build up on a leg belt becomes too long, the DCS automatically discharges fewer products onto that leg. At the same time, it distributes the surplus to the next stations, automatically increasing their discharge capacity. All legs can continue to operate constantly – until the product storage is empty. In this way, the DCS enables maximum storage times with minimum storage lengths – a significant efficiency advantage.”

“Due to the price-sensitive market environment, food manufacturers need to focus on solutions that deliver maximum efficiency gains. Therefore, the Syntegon DCS is designed with a low total cost of ownership in mind”, says Bossel. “Our goal was to develop an innovative and product-friendly system which equips food companies for the challenges of the future. Already we have customers confirm that we have managed to do just that with the DCS discharge station – and a patent for the technology is also pending.”

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