Three applications, one solution
Designed for demanding packaging tasks, the FPC5 from Theegarten-Pactec enables precise and efficient primary packaging in tubular bags.
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Bahlsen has given its „PiCK UP!“ biscuit bar a packaging update and added two bar packers from packaging machine manufacturer Schubert to its existing machine park. A major advantage of this is that the previous secondary packaging made of labels on the top and bottom could be replaced by folding cartons made of cardboard.
Whether for a sudden hunger pang, a short break or the Sunday coffee table - with a large selection of waffles, biscuits and cakes, the Hanover-based biscuit manufacturer Bahlsen has stood for high-quality products for over 130 years. To ensure that the sweet treats reach the consumer undamaged, the company has been working with the Crailsheim-based machine manufacturer for several years.
For the long-established company, savouring and doing good for the environment are not mutually exclusive. In addition to its own commitment to quality and continuous innovation, the biscuit manufacturer has therefore also made the Sustainability at the centre of its activities. The company works with carefully selected partners around the world who act responsibly in the cultivation of raw materials such as cocoa or sugar.
In addition to the ingredients, however, the Product packaging plays a decisive role in sustainable behaviour. For „PiCK UP!“, the popular chocolate biscuit, Bahlsen therefore wanted to new packaging machines to switch production to more environmentally friendly packaging. can be converted.
Folding cartons for chocolate biscuit indulgence
Previously, the „PiCK UP!“ bars were packed in tubular bags, grouped together and labelled. In order to produce more sustainably, the aim was to Replace secondary packaging with cardboard folding boxes in future. Bahlsen was therefore looking for a new automation solution that would protect the delicate biscuit bars in particular from damage and breakage during the packaging process. The confectionery company also opted for thinner films for the tubular bags in order to save material by reducing the film. to reach.
This should also be possible with the machine update. Regardless of the requirements for the packaging machine itself, Bahlsen also had special conditions with regard to the machine location. Space in the production area was very limited due to the many pillars and low ceilings, so that a compact, narrow structure of the line was required.
Two fully automated, flexible bar packers
In order to master the diverse challenges, the Schubert was involved in the packaging development of the folding cartons for this project. This enabled the packaging specialist to optimise the new packaging in the best possible way, particularly with regard to machinability. For example, the Nesting blanks with creasing and scoring lines for quick and easy erection and layout of the blanks optimised. To supplement the existing production lines, Schubert ultimately designed a packaging system for its customer with two identical bar packers, which are installed one behind the other, take up little space in the hall and can be packed independently of each other in parallel can.
Efficient processes in the machine
The entire Packaging process with the key steps of erecting, filling and sealing is now fully automated in the system. Thanks to the robot technology and the use of the Transmodul, Schubert guarantees an interface-free packaging process.
Gentle product handling and a controlled process from start to finish increase the efficiency of the system and minimise waste. At the same time, the redesigned folding boxes and the thinner films of the tubular bags enable the manufacturer to reduce the proud Saving 112 tonnes of plastic. Overall, this represents a major step towards sustainability for the biscuit manufacturer and meets consumer demand for more environmentally friendly packaging.
Robots work hand in hand
With the new packaging solution, the biscuit bars, which are already packed in tubular bags, are now placed in the secondary packaging in the bar packers, which each consist of three machine frames. Firstly, the flat blanks are fed into the system via a magazine. A Depending on the format, the robot removes up to six blanks from the magazine and transfers them to another robot, which erects the cartons. The folded cartons are then placed on the Transmodul transport robot and transported to the filling station. At the same time, the snack bars are fed into the process via a feeder and pre-grouped. A The robot then picks up several bars simultaneously with a suction gripper and transports a predefined number of pieces, depending on the format, into the open cartons. The Transmodul then moves these to the final step, the closing. Here, the sales packaging is closed with a flap presser in a process specially designed for low cartons.
Double effect: sustainable and economical
The Switching to cardboard, thinner films and a new system not only improves sustainability, but is also very economical for Bahlsen. The high-performance solution can process up to 850 biscuit bars per minute. Thanks to the high working precision of the robots, which place the biscuit bars very accurately in the packaging, the new packaging cartons designed without much empty space can be produced. The biscuit manufacturer can also use a variety of formats for its specialities: Outer packaging with eight different product arrangements is possible. A major format changeover is only necessary if the pack base area is changed and can then be carried out in just 20 minutes.
Bahlsen is more than satisfied with the new system. This is because the wide range of box formats and heights and the ability of the robot-assisted machines to process an overcapacity of up to ten per cent from the pre-process, the solution also impresses with its flexibility and efficiency. The company also appreciates the fact that a machine with such high performance was designed by Schubert for a challenging location.
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