packazine · 2019-08-19 · packazine | 5 expensive and too difficult to handle by food production...

FOOD · Issue 01/2008

Nestlé | Delicious chocolate bars from MexicoOsaka | Performance test passed with flying colours Zentis | Know-how from two Bosch plants

packazine

2 | packazine Table of contents | Editorial

www.boschpackaging.com [email protected]

News

Facts & Trends

04 Packaging trends in the food industry

Customers & Markets

Food & Confectionery

06 Nestlé | Sigpack joins Nestlé’s Mexican Wave

10 Pfeifer & Langen | Keeping one step ahead

12 Cadbury Stani Adams | Argentinean Tango in France

14 Zentis | High-tech makeover for classic confectionery

16 Hangzhou Daen Foods | China bags the SVE 2510 LR

18 Lavazza | Value Added Maintenance (VAM)

20 Osaka | Osaka goes crackers over its Bosch line

22 Elledi | Wafer-cutting device with Pack-2000 flow wrapper

Events

25 Food 2008

04 06 10

Cover

Attractive packaging solutions for each taste

Table of contents

packazine | 3

16 22

Dear Readers,

With our extensive range of products and services, we are once again able to utilize

positive economic trends to achieve rapid growth. Global developments demand that,

in doing so, we must take account of Asia, without neglecting other

regions. According to our estimate, by 2015, the Asian economy will

have grown twice as fast as the economies of Europe, and North and

South America.

Bosch Packaging Technology has long been firmly established in

Asia with its own manufacturing sites. This gives us the advantage of

knowing the markets and also customers‘ requirements very well. Ex-

tending our range of products goes hand in hand with expanding our

global presence, which is why we have now opened a state-of-the-art

plant in India, in addition to existing facilities in Singapore, Japan and

China. Bosch Packaging Technology is set for further growth. Our desire to open up

new market segments is supported by acquisitions such as the takeover of Kimaco

SA‘s assets in the processed cheese sector. We are also developing partnerships, for

example with Paal Verpackungsmaschinen for cartoning operations.

The Bosch brand stands for the ultimate in quality and innovation. One way in which

we are demonstrating our innovative approach is our careful use of resources, ena-

bling us to set new standards: for instance, new process and packaging technologies

for the continuous boiling of confectionery are not only minimizing wastage but

also automatically clean the installation following production. A further example of

a new technology is the sealing and welding of flexible packaging materials using

ultrasound. As a result, the packaging process not only requires far less energy, but

we are also achieving improved protection of packaged products as well as an overall

increase in productivity. With innovative packaging technologies like these we are cre-

ating “Technology for Life”, and present ourselves as competent industrial partners.

Our new products can be seen at Interpack, Düsseldorf, from 24th to 30th of April.

Visit us in Hall 6. We look forward to meeting you and exchanging views.

This latest edition of our magazine “packazine” features an Interpack preview with

many examples of successful products and current trends.

I hope you all enjoy your reading.

Best Regards

Friedbert Klefenz

Friedbert Klefenz

President

Bosch Packaging

Technology

Editorial

Pull Pack and Stick-Pack –

The promising combination of two

innovative packaging styles

4 | packazine News Facts & Trends

Evolving a brand

Today, many food brands are at the

crossroads of their evolution. After

years, and in some cases decades, of

developing relationships with consumers,

brands need to find ways of redefining

themselves. Packaging technologies

can be applied that completely redefine

a product category or, in some cases,

create an entirely new product from an

existing brand.

Innovation from the ground up:

The example of Pull Pack

A good example of this kind of pro-active

packaging technology design is the Pull

Pack from Sigpack Systems. The Pull

Pack enables consumers to simply pull

off the short end of the wrapper for

quick access to contents, without con-

tact with the product. This concept was

not dreamed up by designers and then

pushed to packaging developers. Instead,

it was the team at Sigpack Systems,

working with existing equipment and

with knowledge of existing lines, that

wanted to create a new package that

would require minimal alteration of those

lines.

Innovations and perceptions

Evolving a brand sometimes expands

into evolving an entire new product cat-

egory. Bistro Tea (www.bistrotea.com) is

a good example of packaging that plays a

huge part in how the company is chang-

ing the landscape of the tea category.

Using stick pack technology from Sigpack

Systems, Bistro Teas come in perforated

foil sticks that consumers can simply add

to hot or cold water. Together with the

secondary packaging in a Pull Pack (see

picture below) these two innovations

create the perfect packaging. Opening

and consumption of the product will be

a great experience.

What automation brings

Of course, evolving a brand isn‘t as

simple as creating a new design. Cost

of production is also a factor and cost-

consciousness, coupled with creative

design, can be a successful formula for

brand evolution. Once thought to be too

Successful brands build on innovative

and efficient packaging solutions with high

consumer benefit.

Packaging trendsin the food industry

packazine | 5

expensive and too difficult to handle by

food production and packaging facilities,

robots have come down significantly in

price. A robot’s enhanced flexibility adds

to its process and production speeds.

Less is more

Efficiency is also built into the creation

of a packaging line. In this case, less

is often more. For example, Sigpack

Systems recently launched a new flow

wrapping system that is smaller in size

and integrates all of the wrapping and

carton logistics into one machine. In the

past, this required a top loader and a

tray loader, in addition to the flow wrap-

ping system.

Cross over potential

Some of the greatest boons to the pack-

aging side of food could come from the

pharmaceutical industry. One technologi-

cal approach currently being adapted to

different specific requirements in phar-

maceutical industry is Process Analytical

Technology (PAT). PAT works on what is

called closed loop control - nothing ad-

vances to the next step unless a problem

is fixed. True innovation comes from a

thorough investigation and investment in

developing and adapting for example of

specific technologies used to fulfill PAT

requirements.

Conclusion

In the end, consumers decide what is

successful on the market. However,

consumers must be given the innovation

to choose from, in order to advance

the market and assign value. Working

together with Bosch, a packaging expert,

early in the packaging design process,

can gather more success in the store

aisles and in a production environment.

For more information please contact:

Ulrike Probst

Phone +41 52 674 8053

[email protected]

1 DAA Buffer with product distribution

2 Product infeed

3 Splicer preparation

4 Everything under control

Several hundreds of

the delicious chocolate

products are packed per

minute and per wrapper

6 | packazine Customers & Markets Food and Confectionery

1

packazine | 7

Mexico is home to a wide range of top

quality chocolate products, which are

not only manufactured for its domestic

confectionery sector but also for export

to world markets. As market leader in

the Mexican chocolate confectionery

market, Nestlé can comfortably meet

the increasing demand for its delicious

chocolate products by expanding its

production facilities. Knowing that its

own high standards can only be met by

employing first-class technology, Nestlé

is determined to work in partnership

with companies following the same

quality-led philosophy.

Three well-established Swiss companies

were involved with the top-quality deliv-

ery of this project: first, of course,

Nestlé as customer, then Bühler Bindler

as suppliers of the casting plant and last,

but not least, Sigpack Systems, which

was responsible for supplying a complete

packaging system.

Profitable and highly efficient

The installation handles three different

products, each with its own individual

features. The products are pillow-packed

using a cold-seal film, then grouped into

cartons and, finally, again wrapped in a

pillow pack.

In the final phase of the project four

branches will be in use for packaging.

At present, there are two packaging

branches handling all products which

are coming from the DAA storage unit;

coming from the moulding process the

products are fed into the store via a

patented fast-loading unit.

Depending on the nature of the product,

chocolate bars can be stored for a few

minutes. As this creates an ability to

adjust fluctuations in production, the

installation can be operated with a very

high degree of efficiency and extremely

profitably.

Two packaging branches are simultane-

ously fed with several hundreds of

chocolate bars. Sustaining such high

performance levels requires Sigpack

Systems‘ handling technology, as well as

two flexible HSM pillow-pack machines.

Efficient and smart packaging

The packaged bars are then guided

towards the top loader by a further high-

performance element, the feeding wheel.

At top performance levels, the two

loaders can flexibly handle up to several

dozens of trays per minute.

Be honest! While looking at a mouth-watering

chocolate bar, would you think of Mexico?

Not very likely...

Sigpack joins Nestlé’s Mexican Wave

2 3 4

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os augue velit velit pratio

con ea facincil del estrud

ea at et dolore dunt ali-

quat. Nos et augait irilla

feuguer ip er si.

Rat amet prat dit alis nul-

la faciliquat.

High speed wrapper

Flexible Toplader arm

Section of the system

Multi pack


A loading arm then loads the products

and also shifts the trays.

Both tray streams are united for the sec-

ond packaging process by the compact

and economical HCM machine.

The variety of elements - transportation

system, storage units, handling devices,

primary, secondary and tray packag-

ing – are all operated by a singular and

consistent control system, guided by the

same philosophy and combine to form a

thoroughly efficient packaging system.

Flexible system solutions, delivered on

schedule

Nestlé attaches great importance to flex-

ible and upgradeable solutions. This is

why a four-branch system was conceived

for the expansion stage. Thanks to a

clear planning process, precise interface

definition, systems management, layout

adjustment and monitoring of deadlines,

the line went into production – effi-

ciently, on schedule and on budget.

A training program and a supply of re-

placement parts rounded off the product

package. The new installation enables

Nestlé to react quickly and efficiently

to market demands. Other formats are

already at planning stage, demonstrating

the flexibility and resilience of this high-

speed installation!


Urs Schweizer

Phone +41 52 674 6541

[email protected]

packazine | 9

bosch_key_visual_e.indd 1 14.2.2008 14:51:59 Uhr


Pfeifer & Langen uses opportunities created by the new EU Packaging

Directive with Bosch’s PME 4161 BS flexible package maker

Keeping one step ahead

1 High flexibility in terms of packaging size

and material

2 Inline dosing system for maximum

weight accuracy1 2

packazine | 11

In the fall of 2007, EU member states

unanimously amended the regulations

concerning packaging sizes. This means

that producers can now sell around 70

products, such as coffee, butter, sugar

or milk, in any package size, however

small. For the renowned sugar com-

pany, Pfeifer & Langen, this new regula-

tion could not have come at a better

time. It had just acquired a new pack-

age maker and had selected Bosch’s

extremely flexible PME 4161 BS.

Efficient family enterprise

Apart from its well-known sugar and

candy sugar specialty brands for daily

household use, Pfeifer & Langen, a sugar

company founded in 1870, also offers a

number of products for the processing

industry. The “Diamant” and “Kölner

Zucker” product brands and the char-

acteristic company logo, depicting two

sugar loaves, are very well known in the

trade.

Everything in one source

Pfeifer & Langen in Poland was looking

for a new packaging solution for fine

icing sugar. This had previously been

packaged on an installation designed for

pre-fabricated paper bags, which had

two serious disadvantages: the extremely

fine sugar would trickle through the

glued seam of the paper packaging,

and surrounding odors were able to

penetrate through the paper packaging

to the detriment of product quality.

At the same time that it was looking to

improve the packaging process, the revi-

sion of the EU Packaging Directive was

seen by Pfeifer & Langen as an opportu-

nity to expand the market by introducing

new products to new target groups. For

a technological solution, the company

therefore sought to buy a new packaging

machine to help take maximum advan-

tage of these new opportunities, as well

as solving its production problems.

The Bosch PME 4161 BS package maker

proved to be the ideal solution. It meets

today’s requirements for high-quality

packaging and is flexible regarding

packaging sizes, shapes and materials.

This means that Pfeifer & Langen is fully

equipped to meet the challenges of the

future.

Major advantages with composite

packaging materials

It was envisaged that the new packaging

should be very close to the existing one,

regarding design and haptic impression.

This could be realized using a two-

layered composite packaging material.

Unlike the previous paper packaging, the

new design is not glued but sealed, thus

ensuring that the package is trickle and

odor proof.

In order to achieve the best possible

sealing quality, it is essential to ensure

that fine icing sugar does not stick to the

packaging, due to a static charge during

the roll-off process. The film is therefore

electrically discharged and any remaining

sugar is sucked off the packaging by a

dust extractor, so all packaging seams

can be optimally and permanently sealed.

Custom-made solutions – every gram

counts!

Weight accuracy is a vital aspect of the

packaging process, as every gram is

worth hard cash. As a result, the PME

was fitted with a dual weighing and

dosing system. Thanks to the machine’s

modular concept, the integration of such

customized elements poses no problem

at all and underscores the attractiveness

of the PME package maker.

The overall concept of Bosch’s PME 4161

BS enabled Pfeifer & Langen to meet all

its requirements. The company’s future

is now bright as well as sweet!


Martin Kühl

Phone +49 711 811 57480

[email protected]

1


Demonstrating the environment-

friendly aspect of its gum production

equipment, Togum in Reichstett,

France, has been rewarded by the

renewed confidence that Cadbury

Stani Adams has shown at its factory in

Buenos Aires, Argentina.

South America’s leading gum producer

At Togum, we are always proud of our

customer’s success. Our philosophy is to

help every client improve their processes,

in order to break into new markets with

creative products.

Therefore, the recent collaboration with

Cadbury Stani Adams, the leading Argen-

tinean confectionery manufacturer, has

been very rewarding for both partners.

Facing amazing success with its new

sugarless chewing gum, BELDENT, Cad-

bury Stani Adams targeted an increase

in its production volume. Fully satisfied

with the previous Cut & Wrap Line

delivered by Togum a few years ago, the

Argentinean manufacturer again turned

to the equipment of Togum, meanwhile

a part of Bosch Packaging Technology. In

fact, Bosch was the only supplier able

to answer all the customer’s demands:

line flexibility for various chewing gum

recipes, technical support for an efficient

production increase, and environment-

friendly equipment.

Reliable support for high volumes of

production

Demonstrating its know-how in gum

manufacturing, Bosch designed a tailor-

made cooling installation for the existing

BELDENT production line. Considering

the different recipes formulated to

manufacture the chewing gum, the new

equipment gives an increase in produc-

tion capacity by the upstream extruder.

Thanks to the support of Mr. Marcelo

Rymberg, from our local agency Blanko,

all the technical details with regard to

production improvement were fully ap-

proved by Cadbury Stani Adams.

Focus on environmental care

As a subsidiary of the world’s number

one confectionery manufacturer,

Cadbury Schweppes, the Argentinean

gum producer is taking care of the

environmental aspect of its production

equipment. Indeed, Cadbury Schweppes

recently signed the Climate Change

Statement which was launched at the

Global Compact Leaders Summit, in

Geneva, committing the group to taking

practical actions now, to increase the

efficiency of energy usage and to reduce

the carbon burden of the products,

services and processes.

Therefore, special attention is placed

on energy savings and the use of more

environment-friendly energy forms, such

as on-site, renewable energy generation

(solar, wind, biofuel).

Already applied to Cadbury’s production

lines in Rockford (US), Nagano (Japan)

and Karachi (Pakistan), this ecological

improvement is now provided by Bosch

in the Argentinean factory at Buenos

Aires.

Argentinean Tango in France

1 Multi-level WTC cooling tunnel for Cut &

Wrap applications

2 Eco-friendly heat exchanger running with

recycled hot gases for significant energy

savings

3 Individual drive and tensioning device for

every conveyor belt, at each leve 2 3

packazine | 13

Environmental-friendly production

In order to cool the chewing gum rope,

the gum rope flows through a cooling

tunnel that uses recycled hot gases, to

regulate the air temperature, and a more

environment-friendly refrigerant. This

operation reduces the amount of energy

needed and the amount of hot gases

evacuated to the atmosphere.

Renewed confidence

With the update of its BELDENT produc-

tion line, Cadbury Stani Adams has been

able to increase its production capacity,

while taking care of the environment.

The project was developed by Bosch,

with a special focus on the long-term

partnership with this leading player in

the confectionery sector. Both compa-

nies are working hand-in-hand on this

project, just like two tango partners…


Oscar Gomes

Phone +33 388 20 97 84

[email protected]

1 2 3


Convincing performance at

FachPack 2006

At the 2006 FachPack trade fair, in

Nuremberg, Achim Minten, European

Maintenance Manager of Zentis, and his

associate Hubert Kaman, Production

Manager at Zentis Aachen, took the

opportunity to study Bosch’s innovative

solutions in detail. As a consequence,

the foundations were laid for a packaging

project, which would form a new chapter

in both companies’ cooperation.

For the packaging of its popular

marzipan potatoes, Zentis required a

new packaging line to achieve up to 240

pillow-packs per minute, and case pack-

ing them into trays of 36 bags each.

Aside from severe floor space restric-

tions, there were a number of further

project-related challenges: integrating

existing multihead weighers and check-

weighers, adjusting the case packer for

various layer patterns, integrating the

new line into existing carton infeed and

discharge operations and also adhering

to strict deadlines in order to be able

to commission the new installation on

schedule.

Know-how from two Bosch plants

The components of the new all-in-one

installation were manufactured at Bosch

locations in Weert (Netherlands) and

The jam and confectionery manufacturer Zentis can look back on a long and successful history. The company was founded

in 1893 in Aachen, Germany, by Franz Zentis and developed from a supplier for local stores and bakeries into a global acting

company. Its product range includes high-quality marzipan confectionery for the seasonal trade as well as paste products for

the processing industry.

High-tech makeover for classic confectionery

1 Line overview

2 Paloma top-loader

3 Bagmaker SVE 2515 AR

4 Paloma top-loader with transport belts

5 Inside view Paloma top-loader4 5

packazine | 15

Romanel (Switzerland). Uwe Pfander,

Regional Sales Director at Bosch Weert,

is excited about the success of this fairly

recent collaboration: “We were truly

amazed about the quality of the coopera-

tion, right from the start.”

It all had to happen in a close time frame.

While initial tests with the SVE 2515 AR

bagmaker showed that the target

performance could be achieved with two

machines without major modifications,

special grippers had to be developed for

the two Delta robots of the Demaurex

Paloma top-loader, so that each robot

could simultaneously grip two bags and

place them in the trays. Demaurex was

able to implement this customer-specific

modification in record time.

Achim Minten thinks that the result of

this customization is a considerable

achievement: “Moving towards Delta

robot technology meant entering com-

pletely new territory for us, but we liked

the concept from the very start. For an

investment of this nature, we are looking

for a high efficiency and reliable produc-

tion - and we achieved both.”

Hubert Kaman speaks highly about

the accurate on-site configuration:

“Cooperation with Bosch was very close

and highly professional on both sides;

especially the complete incorporation of

our specifications.”

Delivery and installation deadlines were

met, so Zentis was able to start produc-

tion in May 2007. The new installation is

now running multi-shift operations to the

customer’s complete satisfaction. Clearly

this successful partnership will continue

into the future.


Uwe Pfander

Phone +49 711 811 57 478

[email protected]

packazine | 17

China bags the SVE 2510 LR

Of the huge number of food manu-

facturers in China, most are small to

medium sized enterprises. While cost

saving is high on the agenda for these

companies, it is also a priority to deliv-

er high quality food through the use

of the best packaging processes and

materials.

Hangzhou Daen Foods

Founded in 1993, Hangzhou Daen Foods

is a well-known food manufacturer from

Hangzhou in Zhejiang province. The

company mainly produces light snacks

and biscuits, which are very easily spoilt

by moisture and so great demands are

placed on the bag seals of any packaging.

Daen uses gusseted bags, rather than

pillow packs, with the gusseted bag hav-

ing a four-layer seam at its two ends and

on the longitudinal seam, but only two

layers in between.

As a result of the different thicknesses,

the bags are likely to be uneven when hot

sealed and therefore prone to leakages.

Another quality issue is that, to save

costs, the company had already stock-

piled more than 30,000 Euros worth of

cheap, poor quality film, which it needed

to use.

Previously, Daen had selected packaging

equipment provided by a domestic

supplier. However, the problem of bag

leakage had become very frustrating and,

in March 2005, the company contacted

Bosch Packaging Technology (Hangzhou)

Co., Ltd, to find a new solution in the

form of the SVE 2510 LR bagger.

Stopping the leaks

The integrity of the join between the

longitudinal seal and the cross seal is

crucial to prevent leakage. The cross seal

unit in VFFS equipment must therefore

generate high pressure at a stable

temperature. As a result, the SVE 2510

LR adopts a servo-drive control system

to achieve a high, hot sealing pressure

(up to 8000 N) and an optimized hot

sealing time. The SVE 2510 LR also

uses continuous motion technology to

eliminate other possible failings, such

as the packaging material’s instability on

the feeding process leading to possible

leakage.

Another crucial element is the SVE 2510

LR’s special, cross-seal jaw technology.

This jaw was specially designed and

developed to handle the stockpiled

packaging material that Daen is currently

using and is now known internally by

Bosch as the “Daen Jaw”. The Daen Jaw

enables the SVE 2510 LR to deliver 100%

seal integrity, as long as the back seal is

below 4mm width.

Faster and stable production

Daen also immediately experienced

another advantage of the SVE 2510 LR:

fast and stable production. The measure-

ment device was previously matched

with the original domestic packaging

equipment, but the SVE 2510 LR was

able to adjust production speed to

50–60 bags per minute to meet all

the production demands. In using the

continuous motion technique, all the

stations operate continuously, including

film running, bag forming, filling and hot

sealing. This achieves a 30–50 % higher

performance than with the intermittent

motion technique.

With this machine, Bosch Packaging

provides economical solutions in high-

performance packaging for a multitude

of users. This utilization of the most

modern techniques, together with

innovative design points the way far into

the future.


Maggie Zhou

Phone +86 571 8726 5008

[email protected]

High performance SVE 2510 LR:

Continuous bag forming, filling

and sealing machine


Initial stages

For many years, Lavazza has successfully

packaged coffee with lines from Sigpack

Systems, as well as from Bosch Package

Maker. To increase its success, the

company increased its focus on post-

installation services and daily production

support. In 2005, to achieve this next

level of performance and profitability, as

well as to prepare for the future, Lavazza

and Bosch Packaging Services launched

a joint project called Value Added

Main tenance (VAM) to cover the service

needs of today, as well as those in the

future.

The target was clearly defined by:

1. Providing immediately needed serv-

ices on demand

2. Long term availability of local service

resources

3. Assessing requirements for the

competencies and abilities of the

maintenance team

Value Added Maintenance (VAM) is a newly developed system, which

enables you to utilize our combined competencies to assess your

machine’s performance potential and to reach your defined targets using

tailor-made solutions. A cost-benefit analysis lies at the heart of this

operation.

Value Added Maintenance(VAM)

Roll-outAction plan

Target definition

Measure the starting positon

Focu

s P

has

eIm

ple

men

tati

on

Ph

ase

u Action plan u Performance measuring systemu Show the payback u Costs are under controlu Next step

u Step by step approachu Joint decisionsu Define product basket

u Measure the situationu Transparency is requiredu Be ready for success

Knowing the starting position as well as the targets > Focus-Phase Action plan to achieve targets > Implementation-Phase

The way for Value Added Maintenance

packazine | 19

4. Converting maintenance from a

variable cost to a fixed cost, with

a measurable efficiency increase

(payback)

5. Actions must be measurable on an

Overall Equipment Effectiveness

(OEE) base

The project

The concept of VAM is based on the

embedded services pyramid (see picture

left).

Starting with the focus phase (measure

the starting position and target defini-

tion) and working up to and through the

implementation phase (action plan and

control) provides the necessary informa-

tion to calculate a guaranteed payback

for the customer.

Measuring the starting position

uTechnical Audit (technical statement)

uSkill matrix (organizational state-

ment)

In Lavazza’s case, we jointly developed

an overall soft skill matrix, which

included technical skills and packaging

know-how, as well as soft skills such as

knowledge of the Italian language. After

that, we rated the existing staff of Bosch

Packaging, as well as the specialist from

Lavazza, according to the defined needs.

As a summary, we developed a picture

of the level of expertise we already had

available and highlighted areas where

there were gaps in our knowledge. This

was probably one of the most important

steps in our VAM project.

Action plan and control

From then on, for both parties, it was

important to work openly, in order to

move from the starting position, via the

agreed, defined targets, to an overall

committed action plan.

Some of the actions we started were

uOn the job training sessions

uYearly planning for machine revision

uEmbedded engineer packages

uLocal service engineer concepts

After more than two years working to-

gether on the VAM project, every month

has been more successful than the last.

VAM is not a standard, rigid product, it is

more a fully customized flexible concept,

which was developed and is owned by

Bosch Packaging Services.

It is our customer’s aim to get increasing

returns as it invests in the project. The

way that we measure the return is

different for each of our customer’s ap-

plications but the most important factor

is that proactive, planned maintenance

will add monetary value.


Marco Kohler

Phone +41 52 674 74 73

[email protected]

1 2


Located in the west of the Netherlands,

Osaka is a new brand of easily digest-

ible, low-fat, savory rice crackers, with

a novel appearance and surprising

flavors. The entire range is GM-free

and the crackers satisfy increasing

consumer demand for both variety in

snacks and foreign and exotic foods.

The crackers are sold in attractive and

eye-catching packaging, which refer-

ences Japan, the home of savory rice

crackers.

Success breeds success

Having already been impressed with

a previously installed SVE 2510 AR

bag form fill and seal machine, Osaka

returned to Bosch to explore the pos-

sibilities for improvements in the rice

cracker production process. At the top of

its wish list was a desire to improve the

quality of the case packing and a need

to reduce its labor costs. As a result, a

Bosch line was tested within the Osaka

production process for a period of three

months, in order to assess its capabili-

ties. The results were excellent and, in

May 2007, Osaka bought the Bosch

compact case packer CCV 6400 BA.

Flexible production

The installed line also includes an SVE

2510 AR bag form fill and seal machine,

for the production of block bottom bags

which runs on an average speed of 90

bags per minute. Two different forming

sets for block bottom bags are included

in the line and, by also producing differ-

ent heights of bags, Osaka can create a

range of 12 different packages. The bag

weight ranges from 90 up to 300g.

Included in the case packer’s CCV 6400

BA designation are conveyor belts (a

buffer belt and a bag separator belt) for

the transport of the filled bags into the

compact case packer. Also included are

Osaka goes crackers over its Bosch line

1 General picture CCV 6400 BA

2 Detailed inside picture

CCV 6400 BA

3 Example of a filled package 3

packazine | 21

a case erector and a case closer, from

Lantech, and a case elevator, with a

very short footprint, which takes cases

coming out of the case packer up to the

height of the case closer.

The boxes are erected by the Lantech

case erector, which can handle different

sizes of cartons. Osaka uses only two of

the available sizes, including an American

case style, which has a fixed length of

290 mm, a fixed width of 194 mm and a

height of 153 mm. After being closed by

the case closer, the boxes are collected

manually in either a Chep or Euro type

pallet.

Practice makes perfect

During the test period, modifications

were made to adapt the line to the pro-

duct and, as a result, the packing of the

block bottom bags reached speeds up to

90 bags per minute. Another modifica-

tion, in the form of special infeed plates,

was made to match the bag width to the

case width, in order to pack light bags in

relatively small cases.

Approximately 1.1 million bags were

packed by the compact case packer

into more than 120,000 cases and this

allowed performance and quality to be

fully assessed. In theory, the compact

case packer can reach speeds up to 120

bags per minute but, in practice, block

bottom bags cannot be made at this

speed on only one machine.

Visiting the line

We visited Osaka several times with

customers for reference visits and Osaka

is happy to receive further Bosch custom-

ers to see the line as well.


Cees Coppens

Phone +31 495 574 338

[email protected]

1 Product Infeed system

with Pack-2000 flow

wrapper

2 Soft flow product

distribution system1 2

packazine | 23

This year, Bosch Tevopharm has developed a unique application combin-

ing the well-known Pack-2000 flow wrapper with a wafer-cutting device.

The wafer-cutting device has been integrated in the infeed table of the

wrapper and a transport belt system feeds the products to the wrap-

per. The products to be wrapped are wafers, from the leading Italian

confectionery manufacturer, Elledi, which are cut into a certain number

of fingers.

Wafer-cutting device with Pack-2000 flow wrapper

Elledi was founded in 1968 and is based

in Galliera Veneta (Padova) Italy. It began

as a limited partnership but, in 1981,

became a public limited company.

From the outset, the company special-

ized in the production of wafers and

soon attained high quality standards and

produced a wide variety of pastry delica-

cies within the same market segment.

The original wafer production systems

were supplemented in 1983 by new

ladyfinger biscuit production lines and,

in 1988, by shortbread production lines.

More recently, in 1995, Elledi opened a

new plant, enabling it to launch the pro-

duction of a new range, including tarts,

tartlets, soft doughnuts and soft cakes.

How does the machine work?

First, the wafer books are cut in two

directions by the wafer line. After cutting,

the wafer will eventuallly be enrobed.

This means that precut wafers, enrobed

or non-enrobed, are arriving on a

transport belt, with consecutive spacing.

They are aligned with the short side

leading. By means of a soft flow system,

24 | packazine Customers & Markets Food and Confectionery | Events

the products are discharged gently on to

a cross discharge belt to avoid damage to

the product. A unique feature is that the

whole transport belt system is controlled

by the flow wrapper. No separate control

system for the transport belt system is

required.

After discharging the wafers crosswise,

the products are transported, long side

leading, to the cutting device. By meter-

ing belts, the gaps between the products

are closed. Because the buffering belt is

equipped with photocells, the infeed can

run almost constantly. Then, the first wa-

fer on the buffer belt is separated from

the others by a pusher and positioned

before the next pusher. This pucher

moves the wafer through the cutting

device. The whole cutting device is fully

servo-driven and, again, controlled by

the control system of the wrapper. The

infeed chain takes the wafer fingers and

feeds them into the wrapper.

At the end of the line, the products are

wrapped by the Pack-2000, a state-

of-the-art flow wrapper. This unique

machine combines the highest level

of functionality and user friendliness.

Features of the Tevopharm Pack-2000

include pneumatic reel holders and a

fully automatic film tracking system. The

position of the film reel, on the film reel

holder, is fixed by pneumatics for easy

operation. The film reel holder itself can

be moved perpendicular to the machine,

in order to reach an ideal fin seal and

therefore the best packaging result.

Furthermore, a splicer, for easy film reel

switch, and a unique cutting device,

for cutting the film immediately after

splicing, offer customers the highest

efficiency. An encoder determines

the position of splicing and cutting of

the film. This leads to the number of

rejected packs on the discharge belt

being minimized. Of course, typical servo

functionality like “No Product – No Bag”,

which stops the film transport when an

empty pitch appears, and “No Gap – No

Seal”, which stops the rotation of the

cross seal unit when there is no space for

sealing, is standard. Finally, the use of an

attractive cold seal film, in combination

with a gusseting system, gives a tight and

very attractive looking pack.

The whole line is executed in stainless

steel for hygienic reasons and controlled

by the latest Tevopharm control system.

The control system has a minimum

number of rotating parts, such as hard-

disc or ventilators, to give the customer

the most stable control system. The heart

of the control system is a Bosch control-

ler, combining Motion and Logic in one

processor. The HMI no longer has a

separate PC with its own control system

and software, as the required graphic

software is already on the controller.

As a result of this system, the whole

electronic system is more compact, of-

fering the customer greater access to the

machine.

Result

Once again, Tevopharm offered a lead-

ing company a very smooth running line,

combining the transport system, cutting

device and flow wrapper with the high-

est level of functionality and efficiency.


Marc de Vries

Phone +31 10 488 5753

[email protected]

1 Feeding products into

the infeed chain

2 Cutting products into

the infeed chain1 2

packazine | 25

Events Pharma 2008

Events Food 2008

Date Events Location Branch

24. – 30.04.2008 Interpack Düsseldorf, DE all

25. – 28.05.2008 iran food & bev tec Teheran, IR all

14. – 16.05.2008 Packtech & Foodtech Shanghai, CN all

03. – 06.06.2008 Fispal Technologia São Paulo, BR all

24. – 27.06.2008 EXPO PACK Mexico Mexico City, MX all

24. – 27.06.2008 Rosupak / Foodmash Moscow, RUS Food

09. – 11.07.2008 ProPak China Shanghai, CN all

15. – 18.09.2008 Taropak Posen, PL all

23. – 25.09.2008 PPMA Show Birmingham, UK all

30.09. – 03.10.2008 Macropack Utrecht, NL all

13. – 17.10.2008 Agroprodmash Moscow, RUS Food

14. – 16.10.2008 ProPak CAPE Kapstadt, RSA all

09. – 13.11.2008 PackExpo International (PMMI) Chicago, US all

DateEventsLocationBranch

24. – 30.04.2008InterpackDüsseldorf, DEall

25. – 28.05.2008iran food & bev tec Teheran, IRall

14. – 16.05.2008Packtech & FoodtechShanghai, CNall

03. – 06.06.2008Fispal TechnologiaSão Paulo, BRall

24. – 27.06.2008EXPO PACK MexicoMexico City, MXall

02. – 04.07.2008INTERPHEX JAPANTokio, JPPharma/Cosmetic

09. – 11.07.2008ProPak ChinaShanghai, CNall

15. – 18.09.2008TaropakPosen, PLall

23. – 25.09.2008PPMA ShowBirmingham, UKall

30.09. – 02.10.2008TechnoPharmNürnberg, DEall

30.09. – 03.10.2008MacropackUtrecht, NLall

14. – 16.10.2008ProPak CAPEKapstadt, RASall

09. – 13.11.2008PackExpo International (PMMI)Chicago, USall

Customer magazine of the Packaging Technology Product Division Robert Bosch GmbH

Editor in ChiefCentral MarketingUlrike ProbstPhone +41 52 674 80 [email protected]

DesignBOHNER.concept · agency for creative communication & design

PhotosOtlinghaus Fotodesign; Bodo A. Schieren BFF; Bosch Packaging Technology

PublisherProduct Division Management, Stuttgarter Straße 130, D-71332 Waiblingen© Copyright · Packaging Technology Product Division Robert Bosch GmbH

The contents of this publication may not be reprinted except by permission.Subject to alterations.

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