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Bosch Packaging: Flexible biscuit packaging system

It is the first of its kind capable of fast slug to pile changeovers, and vice versa, with the same feeding components.
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Designed for maximum flexibility, the line also features the fastest product count changes currently available on the market. Enabling biscuit manufacturers to meet different global market requirements, the system is capable of producing multiple packaging variations, from smaller on-the-go packages to larger family packs. From distribution through primary to secondary packaging, the line is designed as a single Seamless System for maximized overall equipment effectiveness (OEE). To create the line, Bosch drew from its more than 60 years of biscuit packaging expertise.

“With consumer needs constantly changing, biscuit manufacturers need a single packaging system designed for high flexibility from primary through end-of-line packaging,” said Daniel Bossel, product manager at Bosch. “As the first complete system capable of producing slug and pile packs on the same line, it is truly two-in-one and allows manufacturers to meet current and future market needs. It’s a best-in-class packaging solution that will take manufacturers to the peak of productivity.”

Flexibility from primary through to secondary packaging
The biscuit packaging line features state-of-the-art product handling technology, horizontal flow wrapping and secondary packaging equipment. By using the same feeding components, fully reproducible changeovers between both pile and slug packs can be completed in less than three minutes without changing parts. In addition, count changes, for example, from 14 to 8 biscuits per slug or from two-by-two to two-by-four piles, can be realized in less than one minute. This allows manufacturers to quickly run special promotions with maximum uptime. Additionally, the line is capable of handling different biscuit types and shapes. By achieving high productivity from the short changeover times, the line offers fast return on investment (ROI).

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Complementing primary packaging, the biscuit line is designed for versatile case packing, which can be adjusted quickly and easily to the required format and product configuration with vertical start-up. The case packer is able to run at high feeding rate and products can be supplied flat or on edge. Products can be packaged into RSC or HSC cases (regular and half slotted containers) with retail-ready functionality. Various case closing options are available, ranging from a tape or hot melt solution to the release of unsealed cases for third-party closure. The case erecting, robotic loading, and optional case closing units are all integrated in the case packer, which results in a highly compact machine design. Thanks to the fully flexible feeding wheel, the system can accommodate various factory layouts by positioning the case packer inline, at a 90-degree angle, or also in different angles.

One single, seamless system for maximized OEE
From distribution to secondary packaging, the entire line has been holistically designed as one seamless system. To facilitate high OEE, the speed of all line components is balanced to eliminate bottlenecks, minimize downtime and optimize production flow. It is designed with the operator in mind, with the same look and feel across the entire line, including one human machine interface (HMI) and standard operating procedures. This integrated design concept makes operation of the entire system as simple as operating a single machine, which reduces the risk of operating errors and maximizes uptime.

As one system capable of producing both pile and slug packs, the entire biscuit packaging line occupies a smaller footprint than two separate conventional machines for both formats. This allows manufacturers to save on production costs through reduced maintenance and man-hours.

New innovative sealing technology for high product protection
Meeting all industry sealing requirements, the biscuit line helps protect product integrity and ensures that consumers enjoy the same level of quality every time. The innovative double infeed balances product flow and facilitates gentle guiding to the high speed flow wrapper featuring new amplified heat seal technology. This new sealing process runs at film speeds up to 80 meters per minute for slug and pile packs – nearly double the film speed of existing technology. Additional flow wrapper options like Modified Atmosphere Packaging (MAP), as well as the No Gap/No Seal (NG/NS) function and gusset folding ensure that all market needs are fulfilled.

Hygienic design and gentle product handling
Designed for simplified cleaning, the biscuit line offers high visibility and accessibility for areas requiring sanitation, as well as belts that are simple to clean and replace. Gentle product handling technology decreases product breakage, waste and clean up, resulting in high OEE. The system also features three-dimensional product inspection technology to reject broken biscuits. This prevents crumbs from accumulating throughout the system, which allows a continuous product flow and maximized production uptime.

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