Bosch scalable cookie and cracker packaging systems

Company: Bosch Packaging Technology

Equipment Snapshot: At interpack 2017, Bosch Packaging Technology will debut scalable packaging systems for sweet and savory biscuits for slug and pile pack. They can be easily adapted to changing market needs, allowing trade show visitors to learn which solution is best suited to satisfy their requirements on-site.

“The industry shows an increased demand for flow wrapped cookies and crackers, both on edge and on pile. In view of these trends, Bosch has designed solutions that enable small to large producers to get and stay ahead of the competition,” says Andreas Schildknecht, product manager for horizontal packaging systems at Bosch Packaging Technology. “The modular design of these solutions allows for layout flexibility and scalability, enabling manufacturers to expand their production capacity easily or increase the level of automation – from entry level, hand-fed machines, right through to fully automated solutions.”

Pile packs: Gentle and flexible product handling from start to finish
Bosch debuts its latest solution for pile pack applications. It offers manufacturers increased product protection and the ability to adjust the level of automation to match current and future needs. The system consists of a vibratory infeed, an innovative magazine feeder, a new horizontal flow wrapper and a new Integrated Topload Cartoner.

The Smart Pile Loader (SPL) is developed for gentle product handling from feeding through to collation, achieving enhanced product protection, full product control as well as a continuous product flow. This results in minimized breakage and enables higher production speeds. Due to its ability to automatically and dynamically extract a variable number of biscuits from each magazine, the feeder compensates when the product supply from the oven to the packaging system varies. By extracting missing biscuits from one of the other lanes to build a complete stack, this feature supports automatic lane balancing. In addition, manufacturers can select the desired stack height independently from the number of incoming magazines. This allows for easy changes to package configurations, for example to run special promotions. In order to accommodate inconsistencies in product heights that result from the baking process, the new technology also enables easy adjusting of the stacking mechanism to the varying product thickness, without machine stoppages. Before the stacks are delivered to the Pack 403 flow wrapper, collations of 1 to 4 stacks can be built per pack. Thanks to the wrapper’s improved sealing technology, the biscuits are reliably sealed and protected from moisture, increasing shelf life.

From there, the packs continue to the new Integrated Topload Cartoner (Kliklok ITC), which combines the benefits of three functions in one: carton erecting, loading and closing. Its compact design results in a reduced footprint and simplified operation while increasing speed and quality. Manufacturers profit from lower operation costs. Additionally, the Kliklok ITC provides high format flexibility and runs a variety of carton styles.

Slug packaging system: Flexible and reliable
At interpack, Bosch presents its dedicated system solution for biscuits on edge. Coming from the vibratory infeed, the Smart Measuring Loader portions the biscuits and places them into trays. Then the Smart Slug Feeder places the trays into the infeed of the horizontal wrapper Pack 301 LS. For secondary packaging, Bosch shows the Kliklok SFR endload cartoner with TRAC-i infeed and the new Elematic 1001 SL case packer.

This system starts with a vibratory transport system that assures a continuous product flow at minimal back-up pressure. Depending on the requirements, the measured amount is directly placed in the chain or in the tray. This makes it easy to produce two different pack styles on the subsequent flow wrapping machine.

From the wrapper, the biscuits are delivered by the collating and loading unit into the infeed chain of the endload cartoner. Depending on the required type, orientation and the collation of products, the cartoner can be equipped with several infeed options. Further advantages of the cartoner are: a 25 percent smaller footprint, a patented rotary carton feeder, picking and erecting cartons in the direction of flow. This allows the use of carton board with a higher recycling content, delivering end-users tangible savings in material costs.

In order to complete the Bosch system portfolio and also to address small and medium-sized manufacturers, Bosch developed the universal sideload case packer Elematic 1001 SL. It stands out with regards to ergonomics, robustness and versatility and is designed for handling Regular Slotted Cases (RSC), also known as American cases. Due to its large format range, it offers versatile packaging solutions addressing changing market demands. Thanks to the intuitive Elematic Click changeover and easy machine accessibility, reproducible and tool-less changeovers are executed in less than 10 minutes. The user-friendly features make it easy to operate, clean and maintain the machine. The full servo technology makes it a reliable and efficient alternative for producers of all fast moving consumer goods.

To learn more about the system solutions for cookies and crackers, visit Bosch at interpack in Düsseldorf, Germany, from May 4th to 10th, 2017, Hall 6, booth A31.

This webinar will examine variables factoring into nutritionally improved candy sales, including ingredients, label claims, and alternative sugars. Better-for-you options remain top of mind for consumers who are searching for indulgences, but in a healthier format.