Food - Bosch Packaging Technology

packazine
Food & Confectionery · Issue 2014
Solberg & Hansen | Coffee roaster ramps up for success
Wildlife Sciences | Packaging that’s not “for the birds”
Harada | Rusks gently and efficiently packaged
2 | packazine
Table of contents | Editorial
Table of
contents
07
10
News
Imprint
packazine
Facts & Trends
04
Efficiency and flexibility | Banking on biscuits
Customer magazine of the
Packaging Technology Division,
Robert Bosch GmbH
Customers & Markets
Food & Confectionery
07
Kärntnermilch | Flexibility in the dairy industry
10
Wildlife Sciences | Packaging that’s not “for the birds”
12
Solberg & Hansen | Coffee roaster ramps up for success
14
Essen Production | Tea Time, Sweets Time
17
Harada | Rusks gently and efficiently packaged
20
Mondelēz Ireland | Treating root causes instead of symptoms
Events
23
Editorial team
Central Marketing
Christin Pönisch (Head),
Annette Soyke, Vanessa Lonken
Phone +49 711 811 0
[email protected]
Design
Central Marketing, Karin Schmückle
Photos
B.J.Y.L.D; CN-Photography; raff media group
gmbh; Kati Molin (Fotolia.com); Bosch Packaging
Technology; Allergy Laboratories, Inc.; Harada Ltd.;
Mondelēz Ireland; Novartis; Serum Institute of India;
Siemens & Co.
Publishing
Board of Management
Stuttgarter Straße 130
D-71332 Waiblingen
Events 2014/2015
© Copyright · Packaging Technology Division,
Robert Bosch GmbH
The contents of this publication may not be reprinted
except by permission. Subject to alterations.
Cover
The addition of a vertical packaging line
from Bosch boosts productivity of Norwegian
premium coffee roaster by 40 percent.
www.boschpackaging.com [email protected]
packazine | 3
14
Editorial
17
Dear readers,
This year, the focus of all our efforts at Bosch Packaging Technology is on Interpack 2014, the
world’s biggest packaging technology trade fair. Back at the very first Interpack in 1958, the former
companies Hamac Packmaschinen and Hansella-Maschinen (later Hamac-Hansella), Hesser, Höller,
Magrolo-Maschinen (later Makat), Sapal and SIG’s packaging sector
(later SIG pack) from the food and confectionery sector as well as
the pharmaceutical packaging machinery manufacturers Höfliger &
Karg and Strunck presented their machines. These companies today
have become part of the Bosch family, making Bosch Packaging
Technology unite more than 150 years of packaging know-how
Friedbert Klefenz
under one umbrella. We will keep with the tradition of Interpack
President,
participation this year, too, by using the show as a platform to pre-
Bosch Packaging Technology
sent you our latest innovations and proven portfolio on almost
3000 square meters of booth space.
The entire packaging machinery industry is in a time of change, the defining trends of which are still
ever stricter regulations on production hygiene, constantly changing consumer requirements, and
the imperative to cut costs. We at Bosch Packaging Technology are determined not simply to react
to these changes, but to play an active part in shaping them.
As we work to develop our innovations, we always have your needs as a producer in mind. Come to
Interpack and be inspired by the equipment that Bosch can offer, which will give you the flexibility
to react quickly to changes in the marketplace and help you to meet hygiene regulations. Our equipment is designed to support fast changeover times, quick and thorough cleaning, and simple operation – all of which increases the efficiency of your production process. In addition, we are there to
provide you with advice and tailor the best solution for your specific requirements: That might
involve an upgrade to existing machinery, partial automation of your production line or it could mean
a complete, seamlessly integrated system, that covers not just the production of bars, say, but also
primary, secondary, and end-of-line packaging. We are also there for you once your equipment is in
operation, offering you a range of services that includes everything from maintenance to training.
Our 2013 financial results show that we are on the right track with this strategy. I would like to take
this opportunity to thank you, our customers, for these excellent results. It is the trust that you
continue to put in us, along with the ideas that emerge from our everyday work together, that
motivate us and spur us on to be innovative.
The success stories gathered here in the 2014 packazine will give you a taste of the successful
collaboration. Yogurt, cookies, lozenges or vaccines – Packaged as promised. Bosch.
I hope you enjoy reading the new packazine.
Friedbert Klefenz
4 | packazine News Facts & Trends
Banking on biscuits:
rising demand opens up new
opportunities for
food manufacturers
You might call it a global demand for
packaging standpoint, the growth in
Key mission: automation and flexibility
small treats: The market demand for
this market is boosting the demand for
A high degree of reliable and flexible
biscuits and savory crackers is on
fully automated systems that increase
packaging automation will be important
the rise, creating opportunities for
efficiency and enable more hygienic
for manufacturers to meet the growing
food manufacturers to develop and
processing. In addition, flexible equip-
demand for biscuits. Equipment needs
strengthen their brands. According to
ment and tailored solutions, backed by
to be designed for high-quality output to
Global Industry Analysts, the global
expert support, will help manufacturers
bakery market is projected to reach
leverage the market opportunity in
US$ 410 billion in annual revenue
baked goods and meet ever-changing
by 2015 with the biggest growth for
and diverse consumer needs.
1
crackers and plain biscuits. From a
1
Source: First Research – Cookie & Cracker
Manufacturing Industry Profile (9/23/2013).
http://www.firstresearch.com/Industry-Research/
Cookie-and-Cracker-Manufacturing.html
packazine | 5
meet current and future requirements;
automated lines. It reduces the cost of
With such growth predicted across the
at the same time, it needs to be easy to
labor and allows manufacturers to redi-
globe, consumer tastes are also becom-
use and service. In addition, high overall
rect workers to other important tasks as
ing more versatile. Therefore, incorpo-
equipment effectiveness (OEE) contin-
skills become more refined. New auto-
rating automated packaging technology
ues to be an important factor in pur-
mated lines also come with an advanced
designed for maximum flexibility enables
chasing decisions.
Human Machine Interface (HMI) that is
manufacturers to make quick and easy
For a commodity like biscuits, efficient
easy and intuitive to use, reducing the
adjustments to respond rapidly to con-
automated technologies with high-
time required for training. Over the past
sumer demands. Flexible equipment lets
capacity process lines can compensate
few years, Bosch Packaging Technology
manufacturers rapidly modify production
for low profit margins. In manufacturing
has been implementing such operator-
to suit various levels of product protec-
facilities, where space is also a premium,
friendly technology for the growing
tion and product characteristics, such as
high-speed automated lines enable
biscuit market with manufacturers see-
from pile to slug packs, with little down-
greater productivity within an overall
ing successful results.
time. For instance, packages can be pro-
reduced footprint. With no two manu-
As manufacturers often need to process
duced airtight, gas proof, or including a
facturers having the same needs, it’s
different products on the same line,
corrugated cardboard around the bis-
crucial to work with a supplier capable
packaging systems flexibility is key to
cuits to prevent mechanical shocks. In
of providing a packaging system custom-
handle different pack styles and configu-
addition, there is a range of sealing tech-
made to meet specific needs. Bosch
rations for biscuits. Currently, 75 percent
nologies to accommodate various film
Packaging Technology collaborates with
of biscuits are packed in flexible pack-
qualities. To help improve production
customers to ensure that an appropri-
ages. Typically, pile packaging is used for
and enhance brands, biscuit manufactur-
ate, tailor-made solution is incorporated
formats less than 50 grams, and both
ers and brand managers should take
to achieve production goals and busi-
pile and slug formats are used for pack-
expertise and consultation into consid-
ness objectives.
ages between 51 grams and 100 grams.
eration when purchasing equipment to
As a rule, automated packaging lines
For packages over 100 grams, the vast
make sure that the most efficient and
need fewer operators compared to semi-
majority are packaged into slugs.
appropriate system is purchased.
6 | packazine News Facts & Trends
One example of shifting consumer
need to adopt certain hygienic practices.
fewer materials. Not only are these
demands is the trend towards single-
New automated lines have been
options environmentally friendlier, they
serve packaging. For many consumers,
designed with hygiene in mind. For
help decrease overall costs without sac-
single-serve options convey product
example, steel frames are used and
rificing quality.
freshness since it is meant to be eaten
streamlined designs prevent trapping
As food manufacturers attempt to meet
all at once. Additionally, the pack price
product crumbs in holes and crevices.
the increasing demand in emerging
is more affordable than for bigger packs.
Automation is also inherently more
markets and beyond for biscuits of all
Single-serve packaging also adds conve-
hygienic than semi-automatic operations
types, incorporating automated packag-
nience for busy consumers, such as
because fewer workers come into con-
ing technologies will be crucial for suc-
urban professionals or individuals seek-
tact with food, thus reducing the poten-
cess. Above all, manufacturers need
ing portion control or a snack that can
tial for contamination.
packaging suppliers able to act as con-
be eaten on-the-go.
sultants to help manufacturers find the
Greening for the future
best solution for their requirements.
Focus on hygiene
Food manufacturers are also exploring
Globally, concerns about food safety are
new “green” options to reduce scrap
For more information please contact:
rising, creating new regulations and
and CO2 emissions. This includes biode-
Daniel Bossel
tightening the ones already in existence.
gradable films and reducing the weight
Phone: +41 58 674 7311
This means that food manufacturers
of packaging by using thinner foils and
E-mail: [email protected]
Based in Beringen, Switzerland, Bosch Packaging Systems AG, a
company of Bosch Packaging Technology, brings more than 60 years
of experience with biscuits packaging – expertise that manufacturers
can leverage to help boost brands and seize market share. Bosch’s
new high-speed biscuit line is designed for maximum flexibility and
the fastest changeovers currently available on the market. From
distribution through end-of-line technologies, the biscuit line is a
seamless system that optimizes OEE, taking manufacturers to the
peak of productivity.
packazine | 7
Flexibility in the dairy industry
Kärntnermilch increases productivity with innovative solutions from Bosch subsidiary Ampack
With a clear commitment to freshness,
livelihood for more than 1600 agricul-
as sour cream, mascarpone and lactose-
quality and sustainability, dairy company
tural companies in the region.
free products. In addition, Ramino Käse-
Kärntnermilch is strongly grounded in
Every year, Kärntnermilch manufactures
traum, Drautaler and various naturally
the region Kärnten. The company is com-
more than 100 million liters of milk into
matured cheese such as Mölltaler Alm-
mitted to bringing fresh dairy products
high-quality dairy products and in doing
käse are produced. Organic products
to chillers while being mindful of its
so, uses strict quality inspections and
under the trademark Bio+ account for
responsibilities towards nature and the
state-of-the-art technology to ensure
a third of Kärntnermilch’s production.
environment. With headquarters in
product excellence.
The non-genetically modified organic
Spittal/Drau, Austria, the company is
The product range comprises fresh and
dairy products are highly popular
also a farming cooperative association
longer fresh whole and semi-skimmed
with consumers. The company, which
with 180 employees, making it the
milk amongst other cup products such
was originally founded in 1928 as
8 | packazine Customers & Markets Food and Confectionery
“Oberkärntner Dairy”, is now a market
station, sealing station, foil lid control,
reliable sealing is guaranteed. At the foil
leader and the largest dairy in Kärnten.
snap-on lid station, and packer. With its
lid control, the sealing of the cups is
In order to fulfill high quality demands
different stations, the machine, which
inspected so that only securely sealed
on their dairy products, the company
has been used for production since
cups reach end-of-line packaging.
planned the installation of a new ma-
2013, is optimally suited for the compa-
chine for the filling and packaging of cup
ny’s broad product range.
products, including yogurt, sour cream,
Investment in the future
“The machine from another supplier
fruit yogurt and crème fraiche, and was
Flexible design, highest quality
which Kärntnermilch used for a long
looking for a suitable partner.
Michael Dorner, deputy head of produc-
time previously no longer met the stan-
tion at Kärntnermilch, “Our main goal is
dards which had developed over the
High demands in the food sector
to bring our customers the commodity
past ten years in dairy production. With
Kärntnermilch had high requirements of
of milk and other milk-based products at
the new filling machine from Ampack,
the new filling and sealing machine: It
the highest possible quality. The dairy
we have invested in the future.
should offer maximum flexibility and
products that we produce have to be
Already two weeks after commissioning,
output while also being reliable. Kärnt-
processed as quickly as possible to
production could be moved to the new
nermilch eventually decided upon the
meet strict hygiene standards and must
filling machine”, says Dorner. Since then,
packaging machinery specialist Ampack.
arrive fresh at the chillers. Therefore a
the high-performance machine which
The company has been part of Bosch
filling machine with low downtime and
was developed for the production of
Packaging Technology since 2012 and
minimal machine stoppages is of vital
dairy products has been in constant op-
develops, manufactures, and sells filling
importance to Kärntnermilch. Ampack
eration, 24 hours a day from Sunday
and packaging machines as well as dos-
not only convinced beforehand being a
evening until Friday evening – in three-
ing systems and peripheral machines for
strong partner with developing a cus-
shift operation with an output of 21 000
liquid and viscous food with a world-
tomized filling machine, but also pro-
cups per hour.
wide distribution network. Since 2005,
vided highly reliable technology.”
the company has also been undertaking
From its partner, Kärntnermilch expects
Results speak for themselves
its own research in the area of aseptics
high productivity and maximum flexibil-
With the new machine, Kärntnermilch
and operates a microbiology test labora-
ity in packaging, for example the ability
has increased its production by 40 per-
tory. As packaging machinery specialist,
to also equip cups with a snap-on lid
cent. Because the Ampack machine
Ampack was best able to respond to
during the packaging process. This
enables a higher output, additional time
Kärntnermilch’s requirements of quality
diversity of options in the design of the
opportunities open up allowing Ampack
and reliability.
inline machine’s stations means that
to realize orders at short notice. Time
The Ampack inline machine now used by
Ampack ensures optimum customization
optimization is achieved by way of an
Kärntnermilch is a filling machine de-
to client requirements.
improved production and sanitation pro-
signed with eight tracks, which can fill
As Kärntnermilch packages different
cesses. Moreover, the format of packag-
various products, including different yo-
products with the machine, it had to be
ing can be varied – cups with different
gurts, viscous desserts and sour cream
equipped for this product variety. The
volumes and made from different mate-
in premade cups. Stations include cup
integrated sterilizer ensures the steriliza-
rials can be used, as well as product
infeed, double cup control detection,
tion rate and guarantees that each prod-
changes can be implemented quickly.
sterilizer, piston valve for pre-dosing, ro-
uct meets the necessary hygiene stan-
The filling accuracy of the new machine
tary valve for main dosing, lid placing
dards. Moreover it is fundamental that
amounts to a reduction in unnecessary
packazine | 9
product waste. Also machine operation
became easier for operators due to
larger magazines.
For Kärtnermilch, the project was a success across the whole line: Ampack has
proven itself with innovative technology
and outstanding service. Dorner emphasizes, “We are extremely pleased with
Korbinian Tomschi as project manager
and main contact person, as well as with
his project team. They have worked very
quickly and provided excellent support
throughout the entire project.”
For more information please contact:
Markus Schlumberger
Phone: +49 8231 6005 918
E-mail: [email protected]
10 | packazine Customers & Markets Food and Confectionery
Packaging that’s not
“for the birds”
Wildlife Sciences’ innovative bird food packaging sparks strong growth
Wildlife Sciences, located in Min-
cakes, balls or plugs. Handling and load-
Messy mix
netonka, Minnesota, manufactures a
ing these fat-based products into bird
Traditionally, suet-based bird food has
wide range of suet-based bird food un-
feeders can be a sticky situation. To
been packaged in trays that were then
der its Suet Plus® brand. An energy-rich
make its products cleaner and easier to
lidded. However, this method trans-
food that insect-eating birds love, suet
handle, Bill Gleason, president and
ferred the grimy handling to the cus-
is the hard fat from a beef carcass.
David Pichotta, co-founder of Wildlife
tomer who had to extract the cake from
When used as bird food, it is commonly
Sciences, developed new processing and
the tray when loading bird feeders.
combined with bird seed, corn meal and
packaging for their products.
To eliminate the need for consumers to
other grains and nuts and formed into
have direct contact with the product,
packazine | 11
Wildlife Sciences selected a packaging
demand, Gleason purchased additional
mance of Bosch’s technology and its
format similar to a chocolate bar flow
Bosch wrappers, the Doboy Mustang
customer support, so I purchased the
wrap. This packaging has a serrated
and Doboy Stratus, for the company’s
Pack 101, Bosch’s new entry level flow
edge that enables customers to simply
production line.
wrapper. It’s robust, flexible and easy to
tear open one end of the package and
clean,” says Gleason.
slide the cake out of the package and
Putting a feather in its sustainability
The company now also produces and
into the bird feeder. While simple in
cap
packages the bird food cakes for private
concept, handling the sticky, greasy
The new packaging also offers signi-
label. “The one-piece flow wrap design
products without a tray required cus-
ficant environmental benefits. It uses
allows us to print vivid graphics around
tomized processing technology.
80 percent less packaging by weight
the entire package,” Gleason notes.
Wildlife Sciences also had the challenge
compared to the former tray solution
“Not only does this allow retailers to
of finding packaging technology, specifi-
and is composed of 100 percent recy-
display the product in several attractive
cally a horizontal flow wrapper that was
clable materials. Since the packaging is
ways, but the attractive packaging also
robust enough to form a high-quality
generated from flat rollstock film, it
creates shelf differentiation.” Wildlife
wrap while the machine is coated in fat
requires significantly less space for
Sciences’ business continues to grow
from the suet cakes that contain gear-
transportation, reducing the overall car-
and the company is considering adding
jamming nuts and seeds. After consult-
bon footprint.
another production line in 2014.
mendations, Wildlife Sciences pur-
Positioned for future growth
For more information please contact:
chased a Doboy H-400 horizontal flow
In 2012, Wildlife Sciences’ business had
Paul Garms
wrapper. It reliably packages the prod-
outgrown its existing plant and the com-
Phone: +1 715 246 6511
ucts in a two-shift operation and down-
pany moved to its current location in
E-mail: [email protected]
time for cleaning is only needed once
Minnetonka, MN, which offers triple the
per week.
production space. In 2013 the company
Wildlife Sciences witnessed sales of
added another packaging line. “I have
Suet Plus® surge. To meet increasing
always been impressed with the perfor-
ing with equipment dealers for recom-
12 | packazine Customers & Markets Food and Confectionery
Norwegian premium coffee
roaster ramps up for success
Addition of vertical packaging line from Bosch boosts productivity
by 40 percent
Founded in 18791, Solberg & Hansen, a
sells them wholesale and to private label
Moving from small- to medium-sized
premium coffee and tea importer located
companies, as well as retails coffee un-
operations
in Oslo, makes sure every coffee bean is
der its own brand. In 2012 the company
Winning the coffee bar contract was a
roasted and packaged to perfection. The
won a contract to produce beans for a
key milestone in the company’s strategy
company takes coffee bean selection
private label brand in Sweden that would
for the private label sector, and also
seriously and purchases beans only from
be sold at 150 Swedish coffee bars.
made clear that its packaging operations,
winners of the prestigious Cup of Excel-
To meet increased demand, Solberg &
which included two machines for pre-
lence competition farms in Rwanda,
Hansen installed integrated packaging
made bags, would not be adequate to
Kenya, Guatemala, Costa Rica, El Salva-
line from Bosch Packaging Technology
meet new production demands. To boost
dor, Nicaragua, Colombia, and Brazil.
and was able to escalate productivity
output to the level required, Solberg &
The company then roasts the beans and
by 40 percent.
Hansen knew it needed to move to a ver-
2
Solberg & Hansen opted for an internal valve
for its high-quality stand-up bags, which
enhanced the package’s visual presentation
even further.
packazine | 13
tical form, fill and seal (VFFS) packaging
valves to the inside of packages. “A one-
The netweigher provides one-step weigh-
platform. The company considered sever-
way valve is rather important for preserv-
ing using strain-gauge cell technology,
al manufacturers of vertical packaging
ing coffee freshness,” says Simo Kristidhi,
which produces an exact weight. The
solutions, ultimately choosing Bosch.
roast master for Solberg & Hansen.
KWI checkweigher performs an accurate
“Valves relieve the pressure that builds
weight and quality control check of prod-
Advantages of fully-integrated coffee
up inside the pack as coffee releases
ucts at the end of the packaging line,
packaging line
carbon dioxide, while also preventing
conforming to the requirements of the
After collaborating with Solberg & Hansen
oxygen from entering and affecting the
European Measuring Instruments Direc-
to identify its specific needs, Bosch rec-
aroma.” He adds that the integrated valve
tive (2004/22/EC).
ommended a line that has the flexibility
applicator from Bosch also creates a
Kristidhi says the new packaging line has
to produce four-corner sealed bags as
sealing seam that is barely visible, help-
provided the operational improvements
well as standard stand-up bags and in-
ing to optimize the bag’s appearance.
that Solberg & Hansen sought, while
cludes the Bosch vertical bagger (PME
Choosing an internal valve, rather than
strengthening the coffee’s brands premi-
4001 BG). The bagger runs at speeds of
an external one, the package’s visual pre-
um quality image.
50 bags per minute for 250 gram,
sentation was enhanced even further.
340 gram, and 500 gram bags with four-
For more information please contact:
corner seals. It also produces 1 kilogram
Product savings thanks to highly
Marcus Velezmoro
block-bottom bags at a rate of 45 bags
precise filling technology
Phone: +49 711 811 57850
per minute.
“At Solberg & Hansen, we strongly believe
E-mail: [email protected]
The vertical bagger offers an intermittent
that the packaging should be just as high
motion operation that enables long seal-
quality as the product inside,” emphasiz-
ing times for air-tight bags which enhanc-
es Kristidhi. “With Bosch, we have been
es product protection by preserving the
able to make that happen.”
aroma of the delicate beans. To further
Kristidhi notes that his team took a holis-
enhance operational efficiency, Solberg
tic approach to the packaging process by
& Hansen also purchased an integrated
purchasing a Bosch netweigher (FIW
Bosch applicator (CVA 2000 VIS) to seal
4011K) and a checkweigher (KWI 5000).
Winning a coffee bar contract was a key
milestone for Solberg & Hansen.
To meet increased demand, the company
purchased a fully-integrated
coffee packaging line from Bosch.
1
Source: Dear coffee, I love you, May 2004,
http://www.dearcoffeeiloveyou.com/solberghansen/
2
Source: Alliance for Coffee Excellence,
http://www.allianceforcoffeeexcellence.org/en/
cup-of-excellence/
14 | packazine Customers & Markets Food and Confectionery
Tea Time, Sweets Time
Bosch and Essen Production join forces to offer a new treat
in Russian confectionery market
While the samovar1 is no longer a must
the company acquired an old meat pro-
ing title “Konfetka” (translated as
in every Russian home, the tradition of
cessing factory in Elabuga, the Republic
“sweets”) began its maiden voyage to
tea-drinking is very much alive in the
of Tatarstan, which is a region of the
the tea tables of Russian sweets lovers.
country. Because Russian people usu-
Russian Federation, and converted it
“The new treat has instantly found its
ally drink tea after every meal, the con-
into a cutting-edge confectionery pro-
fans,” said Oleg Sukhorukov, deputy
sumption of sweets is deeply rooted in
duction facility. The company’s first
general director confectionery, Essen
Russian culture. To capitalize on this
confectionery products include a range
Production.
tradition, Essen Production AG, a Rus-
of wafer sweets: “Arami”, “Moya lubi-
When looking for a suitable packaging
sian food manufacturer famous for its
maya Jozy” (translated as “my beloved
line, Essen Production sought out a
Makheev mayonnaise brand, decided to
Jozy”) and “Vafelnaya Konfetka” (trans-
solution that would offer the flexibility
enter the confectionery market.
lated as “wafer sweets”). “Arami” is a
to package a variety of wafer products
glazed wafer treat with whole hazelnuts,
and address ever changing consumer
New plant, new product, new line
“Moya lubimaya Jozy” is a semi-glazed
preferences. After evaluating several
Today, Essen Production offers more
wafer with whole hazelnuts, whereas
packaging suppliers, Essen Production
than 100 products under the Makheev
“Vafelnaya Konfetka” is a bar consisting
chose the solution from Bosch Packag-
brand, including ketchup, sauces, jams,
of three wafers.
ing Technology consisting of the Lane
spices, snacks and mayonnaise. In 2011,
In December 2012, Essen Production’s
after ten successful years in the market,
first confectionery product under work-
1
Traditional Russian tea brewing device, tea urn
packazine | 15
Distribution System (LDS), five inline
one wafer behind another, in perfect or-
that the quality of the delicate wafers is
feeders (Pack Feeder 4) and five flow
der to avoid jams and other related
maintained throughout the packaging
wrappers Pack 401. The Pack 401 ma-
machine stoppages. The wafer rows are
process. Waste and damage levels are
chines are executed in a 4+1 configura-
then diverted to the modular product
therefore kept to the absolute minimum.
tion, which allows for undisrupted oper-
infeed system and transferred to the
ations since one of the five lines is al-
Pack 401 horizontal flow wrapper.
Wafers in all varieties
ways on standby mode and can be used
Bosch’s LDS was specifically developed
Because Russian consumers enjoy vari-
as a backup when another wrapper
for small products and accommodates
ety and choice when it comes to
needs to be offline for maintenance,
random product arrival at high produc-
sweets, Essen Production developed
cleaning or any other issue.
tion rates. Able to process up to 2600
several versions of its confectionery
wafers per minute, the line achieves the
treats. To ensure all of these product
Seamless line
highest possible efficiency by ensuring
variations could be handled efficiently,
To ensure that small wafers are pack-
that products are automatically trans-
Bosch designed a streamlined packag-
aged without bottlenecks and down-
ported from one line part to another in
ing line, which seamlessly integrates the
time, Bosch introduced its LDS (Lane
the event of a breakdown.
LDS, infeed system and Pack 401 hori-
Distribution System). The oscillating
In addition, different modules, such as
zontal flow wrapper. The line’s compact
diagonal positioned side guides stream-
buffering and product inspection,
footprint allows Essen Production to
line the products into four equal rows,
across the entire packaging line ensure
make optimal use of its available pro-
16 | packazine Customers & Markets Food and Confectionery
The tradition of tea-drinking is very much alive in
Russia. Russian people usually enjoy sweets with
tea, such as wafers from Essen Production AG.
duction space. In addition, the horizon-
lows changeovers to a new film reel
manufacturer to successfully enter the
tal flow wrapper features easy to oper-
without stopping the machine. This fea-
confectionery sector and respond to the
ate electronic controls and mechanical
ture not only reduces the total cost of
ever-growing craving for sweets in
reproducible adjustments for quick
ownership (TCO) of the system for Es-
Russia.
changeovers and reduced downtime.
sen Production, but also allows the
“With Bosch we have found a reliable
company to package its new treats more
partner who provides support during
High-speed for growing wafer craving
efficiently and be prepared for growing
every stage of the new product develop-
To prepare itself for rapid increases in
market demand.
ment process; from development, to
production volumes, Essen Production
“Bosch’s solution provides us with the
consultation, to integration and factory
also required its packaging solution
option of quick upscale as wafer treats
acceptance testing,” says Sukhorukov.
to have the ability to adapt from semi-
gain popularity,” says Sukhorukov. “This
“We look forward to continuing our
to full automation, and from medium- to
positions us for our anticipated growth
work together as we further grow in the
high-speed wrapping. The Pack Feeder 4
over the next few years.”
Russian confectionery market.”
ters per minute, whereas the Pack 401
The future is sweet
For more information please contact:
flow wrapper packages around 700 wa-
Essen Production is looking to expand
Leon Arkesteijn
fers per minute. To further maximize up-
its confectionery facility and product of-
Phone: +31 10 4885 727
time, the Pack 401 features an auto-
ferings. Partnering with Bosch Packag-
E-mail: [email protected]
matic film splicer with a sensor that al-
ing Technology has allowed the Russian
is capable of belt speeds up to 120 me-
packazine | 17
Innovative robotics sweeten
production for premium
Japanese confectionery
Gentle and efficient handling of rusks increases production output
The Japanese thank each other for sup-
summer time and Oseibo at the end of
tionery manufacturer based in Takasaki,
port and express their gratitude through
the year.
Japan. High-quality sweets make for
the exchange of gifts. In Japan, gift-
Not surprisingly, the Japanese place
popular gifts, and Mr. Harada aims to
giving is perceived as a form of art, with
special emphasis on packaging their
create confections that are superior in
tradition calling for the Japanese to
gifts. No one knows this better than Mr.
quality. This, he insists, must be re-
bestow gifts on one another at least two
Yoshito Harada, the fourth generation
flected not only in how they taste but
times during the year – Ochugen in
CEO of Harada Ltd., a premium confec-
also in their branding and packaging.
18 | packazine Customers & Markets Food and Confectionery
Confectionery treats from the “castle
packaging technology that could support
Gentle handling is the key
of happiness”
high-speed operations and offer signifi-
According to Mr. Harada, a key advan-
Harada Ltd. started its manufacturing
cant flexibility.
tage of the DELTA C2000 robot is its abil-
operations in 1901 as a Japanese con-
ity to gently handle the brittle rusks, pre-
fectionery (Wagashi) company and later
Delta robots for high-speed production
venting damage and lost product. In ad-
begun bread making in 1946 for a local
The company found a solution with the
dition, unlike the legacy robotics equip-
customer base. Today, with a robust
DELTA C2000 parallel mechanism robot
ment, the delta robots from Bosch can
mail and e-commerce business and 15
from Bosch Packaging Technology. Spi-
combine two rusks together in one stack
premium boutiques across Japan, the
der-like and lightweight, the delta robot
by a chucking method. Using advanced
company’s business has grown ten-fold
is capable of moving objects on a pack-
image detection technology, the delta ro-
in the last decade. Most of its retail out-
aging line at high speeds with pinpoint
bot assesses the exact size of each rusk,
lets are housed within high-end depart-
precision. It is ideal for high-mix, low
determines its gravity point, gradient,
ment stores; however, the company runs
volume applications in which multiple
shape and size, and then matches it with
a few stand-alone boutiques, including
products are processed on the same
a similarly-sized slice for stacking.
one next to its headquarters called Cha-
packaging line. Changeovers can be
This unique double stacking method
teau du Bonheur. In English, this trans-
made quickly and output can be in-
speeds per-cycle operations. Four robots
lates as “castle of happiness,” and as
creased or decreased easily based on
across two lines are able to move 252
Mr. Harada explains, happiness is a core
fluctuating demand.
rusks per minute. Double stacking also
value of his company. “We believe that
Harada installed its first delta robot in
results in fewer crumbs and sugar gran-
customers can feel a small sense of hap-
2007 on the GOUTER de ROI White
ules falling off rusk slices and onto the
piness from a single piece of confection-
Chocolate line. The robot, which was
conveyor, making cleaning easier and re-
ery,” he says.
manufactured and tested in Japan, was
ducing the downtime for maintenance.
Harada’s top-selling product is the
deployed on the line to supply rusks to
The DELTA C2000 robot needs low main-
Gâteau Rusk “GOUTER de ROI”, a line of
the horizontal packaging equipment
tenance in several other ways as well.
crunchy, butter-rich rusks made from
that, in turn, packed them into flow
Other robotics technologies, Mr. Harada
slices of the company’s famous French
wraps.
says, require regular repairs and equip-
baguette bread. Each slice is applied
Today, Harada uses 15 delta robots for
ment overhauls once every two to three
with butter oil, sprinkled with sugar and
both primary and secondary packaging
years. By contrast, the Bosch delta robot
features various coatings depending on
operations. Loaves of bread are baked in
requires no overhaul and is nearly main-
the line. GOUTER de ROI Premium is
tunnel ovens measuring 30 meters long
tenance-free because there is less wear
coated with milk chocolate; other rusk
for half an hour. The bread is then cut
on parts. “As a result, we were able to
series include GOUTER de ROI White
into slices and baked again with gener-
reduce time for upkeep and adjustment
Chocolate and GOUTER de ROI Somme-
ous portions of butter and sugar. The
by 99 percent, while maintenance costs
lier (unsweetened rusk for wine).
delta robots are positioned to move
were cut by 90 percent,” he explains.
In 2003 the GOUTER de ROI product
rusks into horizontal packaging ma-
Mr. Harada reports that the delta robot
won the Golden award at the National
chines, while other Bosch robots trans-
is helping his company to stay ahead of
Confectionery Exposition, and it has
port rusks packaged in flow wraps and
the quality control curve. “By using state-
been hugely successful in Japan. In or-
sort them into retail-ready trays. The
of-the-art manufacturing technology, our
der to meet rising demand and a boom-
high-speed robotics help Harada pro-
products have greater consistency and
ing mail order business, Harada needed
duce 1.3 million rusks every day.
homogeneity. We have improved our
packazine | 19
efficiency and our ability to stabilize pro-
nese. If more support is needed, the lo-
Japan and that Bosch has a team of
duction, while assuring superior quality
cal team of Bosch experts is available
technical experts here as well,” states
for our customers,” he says.
for fast troubleshooting. This local ser-
Mr. Harada.
vice support – both in terms of language
Robots that speak Japanese
capabilities and geographical proximity
For more information please contact:
Tailored for Japan, the DELTA C2000 ro-
– has been a benefit to Harada. “An im-
Armin Radzwill
bot’s HMI allows operators to communi-
portant factor in our decision was the
Phone: +81 3 5466 2550
cate and adjust the machine in Japa-
fact that Delta robots could be tested in
E-mail: [email protected]
20 | packazine Customers & Markets Food and Confectionery
Treating root causes
instead of symptoms
Mondelēz Ireland, the manufacturer of Cadbury chocolate,
wanted to increase the operation effectiveness of its automatic
packaging line for Cadbury Flake bars. Together with
Bosch Packaging Services, Mondelēz Ireland implemented a
very successful OEE (Overall Equipment Effectiveness) concept,
which resulted in an improved performance.
packazine | 21
Mondelēz Ireland is a market-leading
plan. Bosch decided to take their OEE
fectly with the packaging equipment
producer of chocolate, biscuits, gum,
specialist along. “Our expert explained
issues Mondelēz Ireland was experienc-
candy, coffee and powdered beverages.
how the Bosch OEE approach could be
ing in Coolock.
The vast portfolio includes popular
used to help work through the issues of
brands such as Cadbury, Côte d’Or,
the Cadbury Flake bar packaging line,”
Specialized project team
Milka, Toblerone, Jacobs coffee and
says Martin Orgill, head of service sales
Mondelēz Ireland and Bosch selected the
Halls. The factory in Coolock, Ireland,
at Bosch Packaging Services. David
flow wrappers for primary packaging and
produces several key brands including
Lindsay from Mondelēz Ireland adds,
top loaders for a first assessment, as
the popular Cadbury Flake bar. With a
“Since the project required a structured
they were causing most production
tight production schedule, the site de-
method over a certain period of time, a
stops and delays. The customer service
pends on smooth processes and a con-
trustful and open partnership with
team from the UK hub conducted a close
tinuous flow of production. In 2010 the
Bosch was very important for us. We
audit of the situation during actual pro-
packaging line for its Cadbury Flake bars
knew of the OEE idea in principle, but
duction. On 23 consecutive days, they
was not achieving the required output.
we were keen to learn more.”
monitored the selected machines, col-
“At that time, performance was not con-
The calculation of OEE considers three
lected production data from the three
sistent across all machines,” explains Da-
of the most common reasons for produc-
key areas and statistically evaluated
vid Lindsay, production engineering man-
tivity losses: availability, performance
these figures. The results revealed that
ager at the Coolock site. “We worked on
and quality. These factors are expressed
the availability factor was responsible for
the Bosch packaging line ourselves but
in percentages as comparative values
most OEE losses. The evaluated produc-
productivity was still not meeting our ex-
and form the basis of Bosch’s OEE im-
tion data provided a first indication of
pectations. That’s when we decided to
provement project. They are collected
possible causes and showed the fre-
enter into a partnership with the Bosch
with a measuring system over a period of
quency of machine downtime notifica-
team to address the issues.”
approximately four weeks and docu-
tions, which are responsible for availabil-
mented in a chart, showing which indica-
ity loss. Mondelēz Ireland and Bosch set
Continuous approach for sustainable
tor has a negative impact on OEE. Based
up a specialized project team, consisting
improvement
on the causes of those three factors, the
of machinery and product experts from
Mondelēz Ireland invited Bosch senior
Bosch OEE experts can implement a
Mondelēz Ireland as well as engineering
management and the colleagues from
continuous approach for sustainable
specialists and an OEE expert from
the customer service hub in Derby, UK,
equipment improvements and increased
Bosch, to systematically work through
to define a continuous improvement
effectiveness. This concept matched per-
the OEE improvement steps.
22 | packazine Customers & Markets Food and Confectionery
“During our first OEE workshop in
new settings for the different multipack
According to the latest statistics, David
August 2011, we presented an overview
formats.
Lindsay confirms that “performance has
of the findings of our machine analysis,”
improved significantly”. More impor-
Martin Orgill says. David Lindsay adds,
Making the most of plant and people
tantly, Mondelēz Ireland has been able to
“It was a very open and honest ex-
After implementing the defined mea-
sustain this improvement. “This success
change. We shared our goals and de-
sures, the project team carried out a
is based on clear data that we collected
fined clear and measurable objectives.”
more intense equipment performance
with Bosch and the shared know-how
This included a proposal of how to
analysis, based on 90 days of measure-
regarding our machines and production
match the process knowledge of
ments on the flow wrappers and top
cycles. The stages of the OEE approach
Mondelēz Ireland’s engineers best with
loaders, and presented the findings in
were clearly set and well communi-
the know-how of the Bosch machine
the third and last OEE workshop in June
cated,” David Lindsay says. “Our employ-
specialists. “Detecting the symptoms is
2012. “This meeting was very in depth
ees were also great in supporting us.
one thing, but getting to the root causes
and specific to key machine areas based
After familiarizing with the OEE concept,
is the actual aim”, Martin Orgill and
on the fault types and frequencies,”
they saw the need for change and we
David Lindsay agree. In the second OEE
Martin Orgill explains. “We reviewed the
achieved those positive results together.
workshop, the Bosch team evaluated
results of the machine performance with
Treating the root causes instead of only
the impact of the defined causes in a
utmost care to ensure that the correct
the symptoms, together with a reliable
Failure Mode and Effects Analysis
conclusions were extracted.” The OEE
and professional partner, supported us
(FMEA). Answers to questions like ‘How
improvement project from Bosch not
in making the most of our plant and
severe is the effect?’ or ‘How often does
only made it possible for Mondelēz
people in Coolock.”
this issue occur?’ helped to prioritize
Ireland to analyze and prioritize the
potential failure effects, for instance ‘no
machinery issues. It also led to an im-
For more information please contact:
product at infeed’, ‘balance the speed
provement of equipment effectiveness in
Martin Orgill
of the line’, and ‘auto restart proce-
terms of reduced machine downtime and
Phone: +44 1332 626267
dures’. The team then determined mea-
both increased and consistent perfor-
E-mail: [email protected]
sures of improvement, such as creating
mance standards.
PharmTech
11.25. – 11.28.2014
Salon International d'Emballage
11.17. – 11.20.2014
AAPS Annual Meeting
11.02. – 11.06.2014
Pharma Expo
11.02. – 11.05.2014
China Pharm
10.28. – 10.31.2014
Allpack Indonesia
10.21. – 10.24.2014
Propak Cape
10.21. – 10.23.2014
PDA Visual Inspection
10.21. – 10.22.2014
A3P Congress
10.14.– 10.16.2014
ISPE Annual Meeting
10.12. – 10.15.2014
Tokyo Pack
10.07. – 10.10.2014
P-Mec Worldwide
10.07. – 10.09.2014
SupplySide West
10.06. – 10.10.2014
Technopharm/Powtech
09.30. – 10.02.2014
Expoquimia
09.29. – 10.03.2014
Pharmex Asia
09.01. – 09.03.2014
Interphex Japan
07.02. – 07.04.2014
P-Mec China
06.26. – 06.28.2014
Vision Pharma
06.03. – 06.05.2014
P-Mec South East Asia
05.20. – 05.22.2014
FCE Pharma
05.12. – 05.14.2014
Interpack
05.08. – 05.14.2014
Event
Date
P-Mec India
12.02. – 12.04.2014
11/22-11/25/10
(subject to alterations)
Location
Dusseldorf
São Paulo
Jakarta
Stuttgart
Shanghai
Tokyo
Bangkok
Barcelona
Nuremberg
Las Vegas
Paris
Tokyo
Las Vegas
Biarritz
Berlin
Cape Town
Jakarta
Shenzhen
Chicago
San Diego
Paris
Moscow
Mumbai
Branche
General
Pharma
Pharma
Pharma
Pharma
Pharma
Events
Pharma
2014
Pharma
Pharma
Pharma
Pharma
Pharma
General
Pharma
Pharma
Pharma
General
Pharma
Pharma
Pharma
Pharma
General
Pharma
Pharma
(subject to alterations)
Mexico City
Food
Cairo
Food
Propak China
Shanghai
Food
Empack
Brussel
Food
International Pack Tech India
Mumbai
Food
10.06. – 10.10.2014
Agroprodmash
Moscow
Food
10.07. – 10.10.2014
Tokyo Pack
Tokyo
General
10.21. – 10.23.2014
Propak Cape
Cape Town
General
11.02. – 11.05.2014
Pack Expo International
Chicago
Food
11.09. – 11.11.2014
Gulfood Manufacturing
Dubai
Food
11.14. – 11.16.2014
International Food Tech India
Mumbai
Food
11.17. – 11.20.2014
Salon International d'Emballage
Paris
General
01.27. – 01.30.2015
Upakovka
Moscow
Food
02.01. – 02.04.2015
ProSweets
Cologne
Food
03.24. – 03.27.2015
Anuga Foodtec
Cologne
Food
Lead
Date
Event
Location
Branche
05.08. – 05.14.2014
Interpack
Dusseldorf
General
06.03. – 06.06.2014
Fispal Tecnologia
São Paulo
Food
06.10. – 06.13.2014
United Fresh Tec
06.10. – 06.13.2014
Fooma Japan
06.11. – 06.14.2014
Pack Plus
06.17. – 06.20.2014
Expo Pack Mexico
06.19. – 06.21.2014
Afro Packaging
07.16. – 07.18.2014
09.24. – 09.25.2014
09.25. – 09.27.2014
Headline
auch mehrzeilig
Chicago
Food
Tokyo
Food
New Delhi
Food
Events Food
2014/2015
23 | packazine Events 2014/2015
packazine | 23