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

RRPs for candy pouches require robotic case packing

A Ferrara Candy packaging center installs two robotic case packers capable of loading its consumer-preferred stand-up pouches in a range of retail-ready packaging configurations.

Trolli gummy candy is packaged in stand-up pouches case-packed in the Cabrio Case retail-ready package.
Trolli gummy candy is packaged in stand-up pouches case-packed in the Cabrio Case retail-ready package.

Candy packaging has been going soft as of late, with consumers increasingly enjoying the benefits of flexible stand-up pouches, such as their on-the-go convenience and resealability. Retailers like them because they are easy to display, especially when packed in retail-ready packaging (RRP). Because of the increasing popularity of SUPs for sweet treats, Ferrara Candy Co., headquartered in Forest Park, IL, has been growing its number of offerings in this format across its brands, including Trolli and Black Forest gummies, Brach’s chocolates and sweets, and Lemonhead lemon-flavored candy, among others.

Ferrara operates nine facilities across its network. Its Bolingbrook, IL, facility is dedicated to storing and packaging product. The plant comprises a 1-million-sq-ft warehouse with 100,000 sq ft of space for packaging. Its output ranges from a staggering 110 to 120 million lb of product/yr, produced with the help and guidance of 300 employees on 16 packaging lines.

It’s here the candy company installed two SUP machines over a period of time to accommodate the growing trend toward flexible packaging for sweets. With the first machine, operators were manually case packing the bagged products in RSCs. In July 2017, Ferrara installed a second bagger whose high speeds demanded automatic case packing, so they added a robotic case packer as well.

With the new case packer, the candy company also equipped itself with the ability to meet another growing trend: RRP. “Ferrara’s marketing team observed how retail-ready packaging not only creates merchandising ease and efficiency, but also improves the consumer shopping experience by making items easier to find,” says Jim Nicketta, VP-Engineering at Ferrara Candy Co.

The RRP format chosen by Ferrara is Delkor System Inc.’s patented and patents-pending Cabrio Case, a wraparound tray-hood design created from a single piece of corrugated board. The Cabrio Case features a pre-cut tray front that allows the store operator to open the hood in a single, swift motion with no cutting required. Says Jim Tandy, Director-Engineering for Ferrara, the ease of tear-away in a wraparound case and the clean look on shelf were among the features that caught Ferrara’s eye.

To pack the Cabrio Case, Ferrara installed a Delkor MSP-m Series high-speed robotic case packer. In December 2017, it added a second robotic case packer, Delkor’s LSP Series, for its older bagging machine. Explains Eric Williams, Engineer for Ferrara, “The MSP was appropriate for our new SUP [at 180 pouches/min], while the LSP was appropriate for the older SUP [at 80 pouches/min]. The case erector and sealer are the same on both systems. Only the loading section is different.”

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
Coding, Marking, and Labeling Innovations Report
Explore our editor-curated report featuring cutting-edge coding, labeling, and RFID innovations from PACK EXPO 2024. Discover high-speed digital printing, sustainable label materials, automated labeling systems, and advanced traceability solutions that are transforming packaging operations across industries.
Access Report
Coding, Marking, and Labeling Innovations Report