Bosch Packaging Technology implemented a new two-branch packaging system with an intelligent feeding solution for a new caramel wafer line at the Scottish family business Tunnock's.
28 August 2019
The Caramel Wafer Biscuits are automatically grouped into multipacks of four, five, six or eight products. (Image: BOSCH Packaging Technology)
Sir Boyd Tunnock, the 86-year-old chairman and CEO of the world-famous Scottish family business Tunnock's, has relied on Bosch Packaging Technology equipment for many years to guarantee excellent product quality. When he wanted to invest in a new production line to meet the growing demand for Tunnock's products, he once again turned to the packaging experts.
The history of the Tunnock's family business began in 1890 when Thomas Tunnock founded the company. Today, the family business in Uddingston near Glasgow is one of the largest employer in the region.
His Caramel Wafer Biscuits and teacakes are Scottish specialities that have made the company famous worldwide. Most recently, the joint success story of Tunnock's and Bosch Packaging Technology reached the next level: the Implementation of a new two-branch packaging system with intelligent feeding solution.
Tunnock's is known far beyond Scotland for its caramel wafer biscuits. (Image: Bosch Packaging Technology)
Enabling growth and ensuring product quality
Due to constantly growing demand, the company had to increase its production volume. In order to meet the requirements, Tunnock's decided to invest in a Additional production line to invest. In addition to the packaging line, Bosch also supplied a comprehensive service package.
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The aim was to further increase performance and flexibility compared to the existing systems despite the limited space available. In addition, the new system needed to be easy to operate, clean and maintain in order to Fast conversions to make this possible.
Bosch Packaging Technology supplied a flexible and comprehensive packaging system consisting of a storage unit, two horizontal flow-wrapping machines with intelligent feeding and a flexible case packer.
Sir Boyd Tunnock is Chairman and CEO of Tunnock's. He was recently knighted in the Queen's Birthday Honours for his services to business and charity. (Image: Bosch Packaging Technology)
„As quality and reliability are of the utmost importance to me, I only ever buy the best equipment. I am very satisfied with my Bosch packaging lines. That's why I asked Bosch to offer a solution for our new caramel wafer line.“
Sir Boyd Tunnock, the grandson of the company founder
Fast and flexible changeover for a constant production flow
As soon as rows of caramel wafer biscuits have left the enrobing machine and passed through the cooling tunnel, they enter the Sigpack DFR storage unit, which collects products during short downtimes of the downstream machines.
The Sigpack DFR works according to the First-in-first-out principle and unloads the products onto the two downstream packaging branches as required. Each branch consists of a metal detector, a folding machine and a Sigpack HCM multipack flow-wrapping machine with intelligent Sigpack FIT infeed.
The two compact Sigpack FIT feeder modules use Linear motor technology instead of a traditional chain infeed. This enables a fast and continuous product flow to the Sigpack HCM as well as Format change at the touch of a button.
The Sigpack TTMC is characterised by its versatility and flexibility in terms of product and packaging diversity. (Image: Bosch Packaging Technology)
In a constant product flow, the Sigpack FIT carriers automatically transfer and group the primary-packed caramel wafer biscuits into multipacks of four, five, six or eight products. The film is folded around the products and then sealed lengthwise and crosswise. A Automatic film splicer with film end detection enables quick and safe reel changes.
High process safety and reliability
The multipacks are then fed in two lanes from the two Sigpack HCM flow-wrapping machines to the Sigpack TTMC case packer. The TTMC is based on the proven Bosch TTM platform for cartoning. The products are fed, grouped and loaded into the moulded carton.
The machine is characterised by its versatility and flexibility in terms of product and packaging style diversity. Thanks to the patented and tool-free format change concept with vertical restart, the TTMC is easy to operate and ready for use within a few minutes.
The Bosch system achieves a constant production flow. (Image: Bosch Packaging Technology)
Compact footprint and easy handling
Thanks to the compact design of the Sigpack FIT feeder, the total area of the new packaging line could be reduced by as much as four metres compared to the existing lines. Tunnock's decided to realise the installation of the new line with a additional Bosch training package for operating and maintenance personnel.
In a machine training course - consisting of theory and practice - the employees learnt how to maintain and set up the new systems. In addition to the training, Bosch also offers support from its British service centre in Derby. „Since the installation, the Support for always been excellent, as we work closely with the Bosch experts. This is beneficial for both Bosch and ourselves,“ emphasises Stuart Loudon, Project Manager at Tunnock's.
Stuart London (Image: BOSCH Packaging Technology)
„The new Bosch packaging line is very compact. It saves valuable floor space and achieves excellent, efficient results with maximum flexibility. The machines are simple to operate, easy to clean and maintain, allowing us to achieve a continuous production flow. “
Stuart Loudon, Project Manager at Tunnock's
The collaboration continues
After several months of operation, the production volumes of the new line are consistently higher than those of the existing production lines. And the joint projects have not yet been finalised.
„Thanks to the increased efficiency, faster changeover times and lower maintenance costs, we are expecting a Quick return on investment of the new line with the intelligent feeding solution,“ says Bill Gow, Finance Director at Tunnock's. And the joint projects are not yet finished.
Sir Boyd Tunnock decided to invest in two more Bosch machines to support the company's growth. „We want to take our production to the next level. We have known each other's business for more than 50 years. This is a great advantage and leads to an open and trusting business and personal relationship.
With the TTMC, Tunnock's achieves reproducible quality from the first to the last carton. (Image: Bosch Packaging Technology)
Bosch Packaging Technology at FachPack 2019: Hall 1, Stand 204
