Product category:
Food Packaging
News Release from: Bosch SIG Pack Systems | Subject: Packing Machines
Edited by the Manufacturingtalk Editorial
Team on 22 June 2004
Flexible packaging helps confectionery
expansion
A highly flexible packaging line handles a wide range of chocolate bars ranging in weight from 40g to 400g in an extremely diverse range of packaging styles.
Hofer, a subsidiary of the German supermarket chain Aldi, is enjoying the benefits of a new, highly flexible packaging line for its wide range of chocolate bars The increased level of automation, supplied by SIG Pack Systems, has provided Hofer with the capacity to expand into new markets
This article was originally published on Manufacturingtalk on 9 Jan 2001 at 8.00am (UK)
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Hofer, which produces chocolate bars in the Austrian town of Sattledt, recently decided to develop its 'owned brands' range and also to increase its stock turnover.
In a move to modernise and rationalise the chocolate bar production, Hofer looked to comprehensively update its packaging technology.
The main objectives were to decouple the manufacturing and packaging processes, reduce change over times and increase the degree of automation.
To meet these objectives, Hofer brought in the help of leading packaging company, SIG Pack Systems.
SIG Pack Systems devised a system that combined Hofer's existing technology with new equipment.
However, incorporating the greatly varying sizes of products into a single packaging concept presented another challenge.
SIG Pack Systems developed a highly flexible packaging system capable of wrapping chocolate bars ranging in weight from 40g to 400g in an extremely diverse range of packaging styles.
Up to seven different combinations per product format are produced.
The bars are then packaged in pillow packs, classic die-fold packaging and in a multi-pack.
The new system takes 40g bars direct from the discharge end of the production line through a distribution station to the first wrapping machine (SIGDSN).
The conveyer then moves the bars to a buffer system (SIGDAA), which provides a storage time of up to 7.5 minutes, depending on the product.
The product leaves the buffer on two levels and as the bars are transferred, two x-ray machines check them.
Any defective bars are removed from the line.
The split packaging groups each consist of a wrapping machine, an over wrapping machine (SAPALBB), and a pillow-packing machine (SIGHBM).
The over wrappers were already in operation at Hofer.
To meet new requirements for increased production, these were modernised and integrated into the new packaging line.
The 40g bars are packed on the wrapping machine, and then they are clear wrapped downstream by the over wrapper.
Other sizes, depending on demand, can also be easily accommodated.
A special turning unit then orientates the bars length-wise.
The length, width and height of the bars are then checked and, again, any defective bars are rejected.
This ensures the correct number of bars is supplied with maximum efficiency to the horizontal pillow pack machine.
The 40g bars are picked up individually by the feeding wheel (SIGFW) and grouped side by side.
These are then packed three to a single layer in a horizontal pillow pack.
This pillow packer provides the necessary flexibility for Hofer because it is capable of packing the entire product range.
All individual products are then moved to a secondary packaging station.
SIG Pack Systems tailored the new line to meet all Hofer's requirements.
It took suitable precautions to ensure the new equipment was commissioned with no disruption to production.
This was made possible through high-level of coordination and comprehensive layout planning.
The discharge end of the system was also installed first.
This flexible packaging system has provided Hofer with the capacity to expand into new markets, such as Germany and Switzerland.
Until now the company was unable to service these markets for capacity reasons.
Increased demand for a particular product can now be satisfied by an additional shift or by diverting production away from lower volume products.
The packaging system itself is also capable of expansion.
The investment in automated and flexible production enables Hofer to produce large volumes with a few, capable staff.
The low cost production also delivers a competitive advantage.
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