Sustainability is an issue that not only affects everyone personally, but also manufacturers across all industries. One of them is a traditional bakery in Alsace that has been making biscuits for over 100 years. For a more sustainable future and a more efficient and flexible packaging process, packaging machine manufacturer Schubert has equipped the bakery with a real „all-rounder“.
The variations in the material and shape of packaging are practically endless these days. After all, suppliers have to satisfy the increasingly diverse requirements and wishes of their customers. The Packaging machine manufacturer Schubert has been dealing with cardboard packaging for over 50 years and, with this core expertise, has taken on a pioneering role in the industry for sustainable packaging. „Thanks to our manufacturer-independent advice, we are able to offer customers the Switch to sustainable packaging materials to make this possible. Right from the planning stage, we attach great importance to the perfect interplay of materials, technology and expertise, from cardboard trays to paper-based films,“ explains Michael Graf, Director of Schubert-Consulting.
A bakery from Alsace is now also benefiting from this expertise. The bakery with a century-old tradition offers a selection of fine pastries: wafers and biscuits with and without chocolate, in layers or fully coated and all in a wide variety of sizes. Many of them are organic and made from high-quality products. The variety of shapes, sizes and the sometimes small batches used to make packaging a major challenge for automated and sustainable processes. What was needed was a Flexible packaging machine, that can keep up with the wide range and variety of packaging, including sustainable materials.
Every step is scrutinised
In order to be able to offer companies like Elsässer Manufaktur a customised solution, Schubert uses the so-called „5Rs of sustainability“, We scrutinise our products closely at an early planning stage whenever possible. Every single step along the entire supply chain is scrutinised, from the use of raw materials, packaging and finishing to logistics and recycling. „We determine for our customers in a holistic processing approach suitable materials, develop packaging, plan processes and realise them on the appropriate packaging machines,“ explains Michael Graf.
[infotext icon]„The 5R with Schubert“As a partner for sustainability, Schubert is able to optimise its customers„ processes along the entire chain from raw materials, packaging and logistics to recycling. This is based on the so-called "5Rs" - the Principles for waste avoidance“, which Schubert also applies consistently in his own company:
Refuse: Eliminate unnecessary and unsustainable packaging materials
Reduce: Clever packaging solutions for less material usage and less transport
Reuse: Modular, format-equipped packaging systems
Recycle: Recyclable and conventional materials in one system
Rethink: Resource-saving packaging chain from A to Z[/infotext]
The collaboration with the Alsace bakery worked accordingly. Early on, the long-established business expressed a desire to handle plastic and paper-based films, cardboard and plastic trays and U-boards.
The gentle processing of the various biscuit moulds was also in demand. There was no question that the Change of packaging forms and products had to be realised quickly and efficiently.
Switch flexibly between formats and products
An integrated system comprising a denester, pick-and-place robot and the Flowmodul flow-wrapping unit proved to be the best solution for the traditional bakery. The flow-wrapping machine now takes over all the steps in the packaging process in the smallest of spaces.
Long conveyor belts are no longer necessary; instead, the biscuits are picked up flexibly and gently from the product belt by three F4 robots and placed in the trays or directly into the chain. A fourth F4 robot is used variably - for example, when packing in trays. In batches where the products are packed directly into tubular bags, on the other hand, it picks biscuits from the conveyor belt and places them in the chain. The use of robots in the flow-wrapping machine minimises breakage, damage and waste. Schubert's image processing system only forwards data on products of perfect quality to the robot control system.
[infotext icon]Facts and figures about the packaging system at the traditional Alsatian bakery- Compact and flexible flow-wrapping machine
- Output of up to 100 tubular bags per minute
- Suitable for recyclable paper-based films
- Ultrasonic sealing and heat sealing
- Fast and secure format changes[/infotext]
If a format change is required, only a few simple steps are necessary. Whether forming shoulders, carriers, robot tools or tray magazines - all format parts are easy to change and are immediately ready for use without the need for subsequent adjustment. Changing the tubular bag film during operation is also supported by a corresponding mechanism and makes the process very efficient overall.
Equipped for a sustainable future
Flexible robot technology and fast format changes are advantages that are already paying off for the traditional Alsatian bakery today, but also make it fit for the future: The Flowpacker can process not only the usual composite films, but also recyclable mono films. Even with new developments based on paper or compostable films, the Schubert Flowpacker can simply remain in use.
Schubert also has other solutions in its portfolio that enable companies to pack more sustainably. One of these is the PARTBOX, for example. Based on the idea of obtaining sustainable spare parts deliveries and eliminating process waiting times, Schubert has made it possible to print 3D format parts directly at the end customer with the PARTBOX.
