Discover your next big idea at PACK EXPO Las Vegas this September
Experience a breakthrough in packaging & processing and transform your business with solutions from 2,300 suppliers spanning all industries.
REGISTER NOW & SAVE

New flow-wrap system doubles cracker-packing speeds

A new horizontal flow-wrap system for growing Argentinian cracker producer Bagley gently handles product while increasing packaging speeds from 80 to 212 packs/min.

CONSISTENT LOOK. The new packaging equipment produces a hermetically sealed package that resembles the traditional packet seal well known among Traviata consumers
CONSISTENT LOOK. The new packaging equipment produces a hermetically sealed package that resembles the traditional packet seal well known among Traviata consumers

As one of the world’s largest candy producers, Argentina-based Arcor is renowned for the sweet treats it distributes all over the globe. Its affiliated company, Bagley Latin America SA, is of equal renown in Argentina, producing one of the most famous cracker brands in the region—Traviata. This variety of cracker is a staple in Argentinian meals, similar to bread for Europeans. In this manner, Traviata crackers are central to Argentinian consumers of all ages: Children bring them to school, adults consume them with coffee, and everyone uses them to accompany various types of food.

To produce these crackers, Bagley established one of its five cracker production plants in Salto, Province of Buenos Aires, Argentina, referred to as Salto II. The plant has provided 1,000 new jobs since its opening and produces 24,000 tons of Traviata crackers per year to keep up with consumer demand.

To increase productivity at the new plant, Salto II needed a more efficient packaging solution that could handle product gently as well as produce a hermetically sealed package that resembled the traditional packet seal well known among Traviata consumers. Looking for a partner to help meet these challenges, Bagley turned to Bosch Packaging Systems AG in Beringen, Switzerland.

The gentle solution
Since the first half of the last century, Bagley has depended upon Bosch Packaging Systems AG, a company of Bosch Packaging Technology, for its wide portfolio of packaging solutions to handle its confections. Within that time, Bosch has provided Arcor with nearly 400 packaging machines in total, not only for crackers, but also for its candy and chocolate products. Thus, it was only natural that Bagley reached out to Bosch to upgrade its packaging technology for the Traviata crackers. The crackers themselves are a low-cost product, necessitating that a large volume be produced to drive profitability. Therefore, Bagley aimed to increase the production speed to maximize utilization of its equipment.

Adding another challenge, the fragile, rectangular-shaped crackers are characterized by their texture, with many holes and large blisters. Thus, it was necessary to ensure that the increased production speed would not damage the crackers.

To wrap the Traviata crackers, Bosch developed a complete packaging system comprising four wrapping legs that can handle up to 212 packs/leg/min—a significant increase from the previous system’s 80/min. It also incorporated hermetic sealing into its cracker package to ensure product freshness, while the new flow wrap still closely resembles the traditional package with end fold already in the market.

Annual Outlook Report: Workforce
Hiring remains a major challenge in packaging, with 78% struggling to fill unskilled roles and 84% lacking experienced workers. As automation grows, companies must rethink hiring and training. Download the full report for key insights.
Download Now
Annual Outlook Report: Workforce
2024 PACK EXPO Innovations Reports
Exclusive access: Packaging World editor-curated reports revealing PACK EXPO's most groundbreaking technologies across food, healthcare, and machinery sectors. Each report features truly innovative solutions selected from hundreds of exhibitors by our expert team. Transform your operations with just one click.
Access Now
2024 PACK EXPO Innovations Reports