{"id":81397,"date":"2023-06-07T16:52:45","date_gmt":"2023-06-07T14:52:45","guid":{"rendered":"https:\/\/packaging-journal.de\/?p=81397"},"modified":"2023-06-07T12:38:30","modified_gmt":"2023-06-07T10:38:30","slug":"less-plastic-more-cardboard","status":"publish","type":"post","link":"https:\/\/packaging-journal.de\/en\/weniger-kunststoff-mehr-karton\/","title":{"rendered":"Less plastic, more cardboard"},"content":{"rendered":"
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Bahlsen has given its \u201ePiCK UP!\u201c 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.<\/strong><\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t

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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<\/a> 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<\/strong>.<\/p>

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<\/strong>. The company works with carefully selected partners around the world who act responsibly in the cultivation of raw materials such as cocoa or sugar.<\/p>

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In addition to the ingredients, however, the Product packaging plays a decisive role in sustainable behaviour<\/strong>. For \u201ePiCK UP!\u201c, the popular chocolate biscuit, Bahlsen therefore wanted to new packaging machines to switch production to more environmentally friendly packaging.<\/strong> can be converted.<\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t

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The new Schubert packaging machine for \u201ePiCK UP!\u201c (Image: Gerhard Schubert GmbH) <\/figcaption>\n\t\t\t\t\t\t\t\t\t\t<\/figure>\n\t\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t
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Folding cartons for chocolate biscuit indulgence<\/h2>\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t
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Previously, the \u201ePiCK UP!\u201c 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<\/strong>. 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.<\/strong> to reach.<\/p>

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<\/strong>, so that a compact, narrow structure of the line was required.<\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t

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Two fully automated, flexible bar packers<\/h2>\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t
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Bahlsen can save up to 112 tonnes of plastic per year with the new packaging for its biscuit bars. (Image: Gerhard Schubert GmbH)<\/figcaption>\n\t\t\t\t\t\t\t\t\t\t<\/figure>\n\t\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t
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In order to master the diverse challenges, the Schubert<\/a> 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<\/strong> 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<\/strong> can.<\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t

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Efficient processes in the machine<\/h2>\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t
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The entire Packaging process with the key steps of erecting, filling and sealing is now fully automated<\/strong> in the system. Thanks to the robot technology and the use of the Transmodul, Schubert guarantees an interface-free packaging process.<\/p>

Gentle product handling and a controlled process from start to finish increase the efficiency of the system and minimise waste<\/strong>. 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<\/strong>. Overall, this represents a major step towards sustainability for the biscuit manufacturer and meets consumer demand for more environmentally friendly packaging.<\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t

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Robots work hand in hand<\/h2>\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t
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The \u201ePiCK UP!\u201c biscuit bar is protected from damage by the gentle handling of the robots during the packaging process.\n(Image: Gerhard Schubert GmbH)<\/figcaption>\n\t\t\t\t\t\t\t\t\t\t<\/figure>\n\t\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t
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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<\/strong>, 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<\/strong>. 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.<\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t

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Double effect: sustainable and economical<\/h2>\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t
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The Switching to cardboard, thinner films and a new system not only improves sustainability, but is also very economical<\/strong> 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<\/strong> 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.<\/p>

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<\/strong>. The company also appreciates the fact that a machine with such high performance was designed by Schubert for a challenging location.<\/p>

http:\/\/www.schubert.group<\/a><\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/section>\n\t\t\t\t

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More news from the magazine <\/h2>\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t
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\n\t\t\t\n\t\t\t\tIntelligent weighing technology saves resources\t\t\t<\/a>\n\t\t<\/h3>\n\t\t\t\t
\n\t\t\tGreenyard is equipping its high-speed lines with intelligent weighing technology from Mettler-Toledo, thereby significantly reducing the safety margin during product filling.\t\t<\/div>\n\t\t\n\t\t\n\t\t\tRead more \"\t\t<\/a>\n\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/article>\n\t\t\t\t
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\n\t\t\t\n\t\t\t\tFaster to sustainable packaging with AI\t\t\t<\/a>\n\t\t<\/h3>\n\t\t\t\t
\n\t\t\tThe Hamburg-based start-up One.Five uses artificial intelligence to find the optimum packaging faster from the wide range of paper types and coating options.\t\t<\/div>\n\t\t\n\t\t\n\t\t\tRead more \"\t\t<\/a>\n\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/article>\n\t\t\t\t
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\n\t\t\t\n\t\t\t\tPaper packaging for special requirements\t\t\t<\/a>\n\t\t<\/h3>\n\t\t\t\t
\n\t\t\tThe sister companies Kapag (Switzerland) and Oppboga (Sweden) support customers in switching from plastic to renewable raw materials with the renewable Changemaker paper and cardboard grades.\t\t<\/div>\n\t\t\n\t\t\n\t\t\tRead more \"\t\t<\/a>\n\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/article>\n\t\t\t\t
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\n\t\t\t\n\t\t\t\tFibre-based packaging: The path to industrial scaling\t\t\t<\/a>\n\t\t<\/h3>\n\t\t\t\t
\n\t\t\tFibre-based packaging is at a technological turning point. How is series production possible?\t\t<\/div>\n\t\t\n\t\t\n\t\t\tRead more \"\t\t<\/a>\n\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/article>\n\t\t\t\t
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\n\t\t\t\n\t\t\t\tPackaging users | Irony in the luxury segment\t\t\t<\/a>\n\t\t<\/h3>\n\t\t\t\t
\n\t\t\tIn his new column, Harald Braun, our packaging user, shows why luxury products sometimes deliberately forgo glamorous packaging. The deliberate break in image - from grey cardboard to sober typography - can even be a sign of strength in the premium segment.\t\t<\/div>\n\t\t\n\t\t\n\t\t\tRead more \"\t\t<\/a>\n\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/article>\n\t\t\t\t
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\n\t\t\t\n\t\t\t\tMore than a prompt\t\t\t<\/a>\n\t\t<\/h3>\n\t\t\t\t
\n\t\t\tThe start-up Pyx is managed by the founding team Stavros Kyriakidis and Otto Hefner.\t\t<\/div>\n\t\t\n\t\t\n\t\t\tRead more \"\t\t<\/a>\n\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/article>\n\t\t\t\t<\/div>\n\t\t\n\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/section>\n\t\t\t\t<\/div>","protected":false},"excerpt":{"rendered":"Bahlsen has given the \u201cPiCK UP!\" biscuit bar a packaging update and added two bar packers from Schubert to its machine park.","protected":false},"author":1,"featured_media":81399,"comment_status":"closed","ping_status":"closed","sticky":false,"template":"","format":"standard","meta":{"_acf_changed":false,"__cvm_playback_settings":[],"__cvm_video_id":"","rank_math_description":"Bahlsen hat den Keksriegel PiCK UP!\" ein Verpackungs-Update verpasst und seinen Maschinenpark um zwei Riegelpacker von Schubert erweitert.","rank_math_focus_keyword":"Karton,Kunststoff,Bahlsen,Schubert","rank_math_title":"","csco_display_header_overlay":false,"csco_singular_sidebar":"","csco_page_header_type":"","csco_page_load_nextpost":"","csco_post_video_location":[],"csco_post_video_location_hash":"","csco_post_video_url":"","csco_post_video_bg_start_time":0,"csco_post_video_bg_end_time":0,"footnotes":"","_links_to":"","_links_to_target":""},"categories":[28],"tags":[58679,38,60109,32,1487,71,70],"class_list":{"0":"post-81397","1":"post","2":"type-post","3":"status-publish","4":"format-standard","5":"has-post-thumbnail","7":"category-aus-dem-magazin","8":"tag-gerhard-schubert","9":"tag-lebensmittel","10":"tag-magazin-05-06-2023","11":"tag-packmittel-und-packstoffe","12":"tag-papier-pappe-karton","13":"tag-suesswaren","14":"tag-verpackungsmaschinen","15":"cs-entry","16":"cs-video-wrap"},"acf":[],"vimeo_video":null,"_links":{"self":[{"href":"https:\/\/packaging-journal.de\/en\/wp-json\/wp\/v2\/posts\/81397","targetHints":{"allow":["GET"]}}],"collection":[{"href":"https:\/\/packaging-journal.de\/en\/wp-json\/wp\/v2\/posts"}],"about":[{"href":"https:\/\/packaging-journal.de\/en\/wp-json\/wp\/v2\/types\/post"}],"author":[{"embeddable":true,"href":"https:\/\/packaging-journal.de\/en\/wp-json\/wp\/v2\/users\/1"}],"replies":[{"embeddable":true,"href":"https:\/\/packaging-journal.de\/en\/wp-json\/wp\/v2\/comments?post=81397"}],"version-history":[{"count":0,"href":"https:\/\/packaging-journal.de\/en\/wp-json\/wp\/v2\/posts\/81397\/revisions"}],"wp:featuredmedia":[{"embeddable":true,"href":"https:\/\/packaging-journal.de\/en\/wp-json\/wp\/v2\/media\/81399"}],"wp:attachment":[{"href":"https:\/\/packaging-journal.de\/en\/wp-json\/wp\/v2\/media?parent=81397"}],"wp:term":[{"taxonomy":"category","embeddable":true,"href":"https:\/\/packaging-journal.de\/en\/wp-json\/wp\/v2\/categories?post=81397"},{"taxonomy":"post_tag","embeddable":true,"href":"https:\/\/packaging-journal.de\/en\/wp-json\/wp\/v2\/tags?post=81397"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}