food & confectionery · issue 2015 - webpackaging · 2017-05-26 · amul dairy | “the taste...

2 | packazine Table of contents | Editorial

www.boschpackaging.com [email protected]

Customer magazine of the Packaging Technology Division,Robert Bosch GmbH

Editorial teamCentral MarketingAnnette Soyke (Head),Christin PönischTelefon +49 711 811 [email protected]

DesignCentral Marketing, Karin Schmückle

PhotosB.J.Y.L.D (picture editing); Bosch Packaging Technology; denio109 (Fotolia.com); Ralf Grömminger Fotografie GmbH; vege ( Fotolia.com); Zamzam Images (Alamy.com); Photographee.eu (Fotolia.com)

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© Copyright · Packaging Technology Division, Robert Bosch GmbH

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

Imprint

packazine

News

Facts & Trends04 Bosch Packaging Services | Serviced as promised

Customers & Markets

Food & Confectionery07 Brüggen | Behind bars

10 Interbos | Breaking the mould

12 Amul Dairy | “The Taste of India” all wrapped up

14 Mondelēz South Africa | Upgrades avoid unplanned downtimes

17 Big Heart Pet Brands | A flexible solution for Fido’s fresh treats

20 Swizzels Matlow | Sweet smell of success

22 Unilever | That’s a wrap!

Events

25 Events 2015/2016

CoverBig Heart Pet Brands, the pet food and treat

company is well-known for its line of iconic Milk-Bone biscuit treats

07 10

Table of contents

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Dear readers,

Nothing is more important to us than offering you exactly the products and services you really need. Whether you are developing a new drug, implementing a biscuit line, or want to educate your staff in specialized trainings – tech-nical expertise, comprehensive consulting and services make Bosch Packaging Technology your trusted partner.

Numerous examples in the new packazine show how we do this. They also depict the broad range of products you can produce, process, fill and package with our solutions all over the world. A German producer of muesli bars, for instance, uses the entire portfolio for food manufacturing and packaging. In Vietnam, our machines support compa-nies and farmers in sustainable management.

While a leading European contract manufacturer for parenterals relies on our inspection technology, the report from Saudi-Arabia shows what we understand by line competence. This is also emphasized by our appea-rance (booth C71, hall 3.1) at Achema 2015. Find out how Bosch supports pharmaceutical companies in the deve-lopment and production of oncology drugs or insulin pre-parations with tailor-made high-tech solutions – true to the motto “processed, packaged and serviced as pro-mised. Bosch.”

Enjoy reading the new packazine.

Friedbert Klefenz

17 22

Editorial

Friedbert KlefenzPresident, Bosch Packaging Technology

4 | packazine News Facts & Trends

Serviced as promised

Increased equipment availability and maximum output at reduced production costs. Sounds utopian? It’s actually not! Whether customers call a biscuit packaging line or a filling line for oncology drugs their own, all equipment must produce, package, or process a maximum number of items within a few hours or even minutes. Each instance of downtime costs valuable production time. To ensure that drug, food, and confectionery manufacturers can work with reliable equipment and high availability, after-sales services experts play a crucial role as partners.

Regionally and locally on siteIndustrial production is progressing by leaps and bounds. Globalization and increasing connectivity are changing day-to-day production of companies from all sectors. Asia in particular, but also parts of Latin America, Eastern Eu-rope, and Africa are currently experiencing an economic boom. Due to a growing population and higher incomes, the demand for food and medicine is rapidly increasing. As a result, manufacturers are moving parts of their pro-duction to the so-called emerging markets, and regional

Bosch knows the future industry requirements and has developed a comprehensive service range, such as trainings, to support customers in achieving their goals

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companies are increasing their production capacity. In parallel with this development, there is a growing demand for processing, filling and packaging machinery – and consequently for comprehensive services.Bosch is where the customer is. In accordance with this credo, the service of Bosch Packaging Technology is also represented in the growth regions. The expansion of existing regional branches and the creation of new ones allows for short distances, fast delivery times, and intensive customer contact. The expansion of service locations in China and South America, for instance, offers local companies an even more personal and faster support that is tailored exactly to their requirements. At the same time, investment in well-trained staff is just as important as rapid delivery of the required spare parts. Therefore Bosch relies on staff who are familiar with the characteristics of the respective regions, who speak the

native language of the customer, and who provide the appropriate service at a local level with the usual high Bosch quality. This builds trust and lays the foundation for long-term and cooperative customer relationships.

The keyword is “proactive”This situation is likely to be familiar to producers of pharmaceuticals or food: a machine sends an unexpected error report, and production has to be stopped suddenly. Defects often cannot be immediately tracked down, or the required spare part is not in stock. Such worst case scenarios – and the costly downtime associated with them – can be prevented with a proactive approach. Preventive maintenance ensures that potential problems are detected and corrected early. In addition, anticipatory modernizations can help bring the equipment up-to-date, considerably prolonging their lifetime. The projects of

6 | packazine News Facts & Trends

imparts its long-standing and extensive expertise to customers. An important foundation was laid by the Bosch Packaging Academy, which was founded in March 2014. The global training platform provides customers and employees with a common knowledge pool for the entire equipment range from Bosch Packaging Technol-ogy. The emerging markets currently have a high demand for trained personnel. For this reason, the competence centers and country academies offer a comprehensive seminar program for the product areas of pharmaceuti-cals, food and confectionery, as well as for industry-wide issues.Individual trainings at the customer’s site also aid in the instruction of new employees and convey practical knowledge about the equipment to machine operators around the world. The employees of Bosch Packaging Technology use the trainings all over the world to enhance their knowledge on an ongoing basis and to provide customers with fast and qualified assistance – an offer which increases employee motivation and leads to high customer satisfaction.

Getting the mostJust as Bosch supports customers in achieving optimum production results, Bosch Packaging Services also con-tinuously seeks to evolve its offerings to ensure reliable and fast support. Bosch Packaging Technology has set the target to further expand its leading position in processing and packaging technology globally by 2020. In accordance with this goal, Bosch Packaging Services has big plans for the coming years.Whether it comes to individual training, fast delivery of spare parts, development of preventive maintenance strategies, or complex line analyses – all strategic steps primarily serve one objective: supporting customers all over the world with innovative products and excellent service to get the most out of their equipment – in line with the motto “Serviced as promised. Bosch.”

For more information please contact:

Martina Jahnke

Phone: +41 58 674 74 73

E-mail: [email protected]

Takeda in Brazil (page 10, pharma part) and Mondelēz in South Africa (page 14) show how timely modernization prevents the risk of prolonged downtime.If unexpected incidents occur despite preventive measures, Bosch’s Remote Service enables fast and cost-effective intervention. In many cases, the visit of a service technician can be avoided or prepared more precisely. Data security is paramount for the connection of the service experts with the equipment. For example, the new Remote Service Portal operates with a secure VPN connection and certificate-based encryption. In addition to the further development of the service portfolio, new consulting concepts are being created for customers worldwide. Together with partner companies, Bosch conducts complete line analyses. The results provide insight into performance, maintenance costs, and processes – the key to appropriate measures such as preventive maintenance agreements, modifications, or optimized spare parts management. The results are reduced costs and higher machine availability.

Bosch Packaging AcademyTechnical expertise is an important factor when it comes to optimal production processes. This is why Bosch

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So much has changed since 1868 when the brothers Heinrich and Johannes Brüggen founded the company H. & J. Brüggen KG in Germany’s city of Neumünster. Instead of processing traditional milled products like oat flakes, today’s business is all about developing innovative recipes and processes for new products. Some 620 employees work at the 8500 square meter main plant in Lübeck near Hamburg, producing a broad product portfolio. Among the most popular products, however, are

various forms of bars and muesli bars. To cope with the ever-growing demand for bars, Brüggen was looking for a new production line to manage the entire process – from bar manufacturing to retail-ready packaging.

A partnership built on experience and expertiseFor several years Brüggen has relied on Bosch technolo-gies to package its products and has valued the quality, reliability and service received. Based on the positive

Behind barsBosch teams up with cereal bar manufacturer Brüggen

to deliver best quality

8 | packazine Customers & Markets Food and Confectionery

experience with Bosch and its innovative and flexible technologies, Brüggen placed the order for a complete bar production line. Several Bosch sites were involved in the implementation of the project: the processing technology was provided by Viersen, Germany, flow wrapping and packaging into cartons was supplied from Beringen, Switzerland, and the packaging into retail-ready cases was managed by the Remshalden site in Germany’s Swabia region. A continuous production process for the entire bar manufacturing and packaging operation was the deciding factor thanks to the modular aspect of Bosch’s design – the smooth alignment of interfaces and systems ensures simple and reliable operation.

Continuous productionTo process 600 bars per minute following different recipes and in various forms, Bosch installed a Contiline for the mass preparation stage and the continuous mixing, shaping, cooling, cutting and coating. Once the binding agent has been prepared, a WRM mixer with counter-rotating mixing shafts gently blends it with the respective dry ingredients. The prepared bar mass is fed into the WRF two-roller former, which ensures a uniform temperature and therefore steady product consistency, as well as ensures an even mass. A profile roller then forms the bars’ desired shape. After this, the WRC cooling tunnel chills the slab to the optimal cutting temperature before sending it to the WRL longitudinal cutting machine, which slices it into individual product strands. The strands are fanned out using a spreader system and fed into the cross-cutting machine. A trim optimizing feature

helps to minimizes product waste. Depending on the bar type, the products are then either dipped in chocolate or decorated. For Brüggen, the easy accessibility and cleaning of the various Contiline components were major considerations. “With the Contiline, we can produce 300 different product types, and the tool-free operation enables changeovers in just a few minutes,” says Hanno Brüggen, managing director of H. & J. Brüggen KG.

Ready for retailOnce processing is complete, a cooling tunnel guides the rows of bars towards a Sigpack DAA Accuflex distribution accumulator. The accumulator regulates the product flow between the processing and packaging stages and also helps to transport the products from the upper floor of the Brüggen plant to the floor below. This ensures a continuous supply of the packaging machines compensat-ing any fluctuations. A discharge station then directs the bars towards the high-speed horizontal flow wrapper with rotating heat-sealing jaws. The diligent product handling technology allows for synchronization without bottlenecks, even with sticky products, while the rotating heat-sealing jaws create hermetic seals. Following primary

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of several different components, the machines combine so smoothly that it significantly reduces any planned downtime due to product changes or cleaning. The new system allowed us to reduce cleaning time from seven hours to two,” explains Hanno Brüggen. “With Bosch at our side, we will be able to offer innovative pack styles and high-quality products long into the future."


Peter Dressler

Phone: +49 2162 248 476


packaging, the top loader collects the products using a vacuum wheel and arranges them in groups before insert-ing them into erected cartons. These are then closed and checked by scales. Finally, the Elematic 3000 case packer, featuring wrap-around technology, collates the cartons and packs them into retail-ready packaging with tray and hood. The tray and hood are simple to handle for retailers in terms of opening and shelving the case. The machine gives Brüggen the flexibility to choose between 12 differ-ent formats and thereby satisfy customer needs. Machine operators can switch between formats quickly and easily, without needing tools, in just 15 to 20 minutes. As a result, Brüggen is able to offer a multitude of collations in different shapes and sizes – from small packages contain-ing a collation of 12 cartons arranged in a row, to large collations with 21 cartons. “Throughout the entire process, Bosch has proven its value as a partner. Though the production line consists

Founded in 2012, Interbos is one of the top dairy produc-ers in Vietnam. The company’s main facility in Hung Yen, near Hanoi, is specialized in premium dairy products, including crème desserts, fresh cheese and nutritious yoghurts. To provide the highest product quality possible, Interbos raises its own cattle and produces its own milk on several company-operated farms. The company also helps local farmers by sharing best practices for sustainable farming, and offers financial aid for farmers. While the dairy industry in Vietnam continues to grow1, many producers still face challenges when trying to bring

their products to market. As a result, few consumers have access to quality and safe dairy products, so the majority of baby food and desserts are imported from Europe.

A new chapterIn line with Interbos’ philosophy of delivering premium products to its customers, the company set its sights on breaking the mould for the traditional yoghurt packaging in the country. With the new aseptic filling and safe

Breaking the mouldBosch and Interbos join forces to bring high-quality dairy products

with extended shelf life to Vietnam

1 http://www.euromonitor.com/dairy-in-vietnam/report


packaging the risk of quality loss and spoilage can now be avoided, especially during transport and storage without sufficient cooling. The production line consequently would need to allow Interbos to develop a formula that does not use artificial flavors or preservatives and still ex-tend the product’s shelf life for a minimum of six months outside of the cooling chain, despite the country’s humid and warm climate. Recognizing that many European equipment providers have had a great deal of expertise to offer in these important areas, Interbos started its search for a partner there. After considering several suppliers, the company selected Bosch Packaging Technology for the project, trusting that a well-known brand on the global market will deliver the same results to the Vietnamese dairy producer.

The quest for qualityBosch focused on developing a versatile solution: A pro-duction line centered around Bosch’s TFA 4818 aseptic thermoform, fill and seal machine which features a fully enclosed tunnel, eliminating the need to invest in a clean-room environment and did not require a large footprint. The machine allows the aseptic packaging of commercially sterile products for ambient temperature storage without the need for preservatives, retort processing or refrigera-tion. Consistently high product quality that meets FDA and VDMA standards is provided through high-precision cup wall-forming and the fully enclosed aseptic tunnel with continuous monitoring for over-pressurized sterile air. Machine sterility is also maintained during product changeovers and a series of safety features ensures the machine shuts off automatically in the event of an incident that may compromise a sterile environment.

Production can only continue upon completion of a sterilization program. “The experts from Bosch have supported us immensely during the development process,” says Tuan Khai, founder and general director at Interbos. “With two local techni-cians available, somebody was always there to provide immediate help.” To help prevent operator errors that could lead to contamination issues, Bosch integrated two precise, full-metal piston fillers capable of running maintenance-free for the first year. Ease of operation was also ensured through low overall maintenance require-ments and an intuitive HMI in Vietnamese. In addition, roll stock materials minimize storage space, ensuring cost-effective packaging and handling.

The start of a journey“With the first aseptic thermoform, fill and seal machine in Vietnam, we are able to provide high quality, fresh products with a shelf life of 12 months – double our initial requirement – on a single production line, without the need for a continuous cooling chain”, says Kai. “The new line has delivered everything we had hoped for: the product is well received by our customers and even other dairy producers were amazed of its high quality. But our journey has just begun. Now that we have a line capable of delivering to FDA and VDMA standards, we have the opportunity to produce much-needed new products, such as baby food, here in Vietnam in the future.”


Robert Fesl

Phone: +49 711 811 57229


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“The Taste of India” all wrapped up

Sometimes the greatest market success stories begin

with just one person

Take India’s Amul Dairy for example, the country’s larg-est food brand, whose evolution has helped shape the entrepreneurial spirit among local farmers. It all started in 1946 when Sardar Patel seeded the idea of forming Amul Dairy cooperative with the goal of linking the country’s milk producers with consumers, reducing price variations and giving farmers control over their development. Its introduction has significantly changed the lives of many Indian farmers and their families and helped support the country’s economical growth. Now, each morning, 3 mil-lion women from 17000 Indian villages bring milk worth more than US$ 8 million to the local cooperative. From there, it is transported to the District Milk Producers’ Union and eventually delivered to Amul Dairy regional plants across India. Bosch Packaging Technology has played a part in this great story in several ways, including by supplying the renowned dairy products manufacturer with a DCP 0600 machine dedicated to processed cheese filling and packaging.

Exploring new frontiers The cooperation between the two companies started back in 1996 when Sapal, a Bosch Packaging Technology company, provided Amul Dairy’s plant in Kaira District in Anand, Gujarat with its first ML-2 machine for dosing and packaging processed cheese. Bosch’s high quality technology and attentive service has led to a strong business relationship. So in 2013, when the dairy manu-facturer decided to expand its productivity, it reached out to Bosch for consultation. By offering speeds up to 500 cheese portions per minute, the DCP 0600 increased the productivity of the dairy’s processing line by 40 percent compared to existing line. This speed, coupled with Bosch’s customization capabilities, were key factors in the selection of this solution by the Indian manufacturer. “The Amul brand of plain cheese is different than any other dairy product available in Western countries,” explained

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Dr. K. Rathnam, managing director of Amul Kaira District Co-operative Milk Producers’ Union in Anand, Gujarat. “It is 100 percent natural cheddar cheese, distinguished by its unique consistency and taste. The Bosch team recog-nized our unique requirements and developed a packaging solution tailored just to meet Amul’s requirements”.

Packaged to perfectionBosch’s DCP 0600 machine doses and packages processed cheese in premium square-shaped portions weighing 25 grams each. The first step in the production process is to form the aluminum shell, which is then precisely filled with the liquid product, ensuring material and product savings. The DCP 0600 solution also ensures that folds are perfectly symmetrical and minimizes consumption of wrapping materials thanks to its folding boxes in which all folds are processed simultaneously at any speed. Eventually the square portion of the processed cheese is hermetically sealed at more than 120°C, forming a consumer-friendly, easy-to-open wrap thanks to the tear-tape. Along with the DCP 0600 dosing and packaging

machine, Bosch installed a fully automatic cartoning machine (supplied by its Italian partner, Grandi) that can pack the portions up to four layers at maximum one kilo-gram per carton.

More than just good looksIn the end, the brand, which uses the tagline “The Taste of India”, has packaging capabilities that suitably reflect its premium image. But there’s more to the package than how it looks. The high level of product protection it offers also makes the new wrap style stand out compared to other cheese brands available on Indian market. “If the milk volumes keep rising between 2015 and 2016, we will definitely consider investing in a new DCP 0600 machine,” summarized Dr. K. Rathnam.


Louis Monnickendam

Phone: +41 21 633 55 81



Upgrades avoid unplanned downtimes

Bosch secures availability of twenty year old horizontal flow

wrapping machine for Mondelēz South Africa

Just like a car should be checked and inspected regularly by specialists, packaging machinery also requires regular maintenance to preserve the full potential. The older a machine gets, the longer it may take to order and incorporate spare parts or machine components as the availability decreases in parallel with the age of the machine. This is especially true for hardware components of control systems, which are at the heart of every flow wrapping machine. Spare parts might even be impossible to find, putting production at a very high risk.Mondelēz South Africa, the largest confectionery manufacturer in the country, faced this critical situation at its site in Port Elizabeth. The company is market leader

in the South African chocolate, candy and bubble gum industry with many internationally established brands like Cadbury Dairy Milk, Oreo or Halls. Opened way back in 1926, the site in Port Elizabeth today is one of the biggest company facilities with around 1000 employees. The famous Cadbury chocolate bars and candies are produced on-site and sold throughout South Africa, as well as in several neighboring countries such as Botswana, Namibia or Zimbabwe.

Nearly twenty years of reliable performanceThe confectionery manufacturer utilizes a Sapastoc stor-age unit from the Bosch Packaging Technology subsidiary

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Sapal and its Sigpack HSM horizontal flow wrapping machine to package the chocolate bars. Both machines have been a reliable and important part of production for almost twenty years. The storage unit feeds the wrapper with unpackaged bars. By storing the chocolate bars over a specific timespan, it ensures an uninterrupted packag-ing flow. The Sigpack HSM wraps up to 1200 chocolate bars in hermetic, loose or tight-fitting pillow packs per minute. A constantly high and consistent process speed of the product feed with vacuum enables Mondelēz to gently handle different kinds and sizes of chocolate bars. An ad-ditional pull and pack module perforates the packages to facilitate a consumer-friendly handling of each chocolate bar. “Since the machines’ performance exactly met our expectations for a very long time, we did not consider modernizing or rather upgrading it,” says Daniel Matthee, site engineering manager at Mondelēz South Africa.The confectionery manufacturer was always in close

contact with Eduardo Dos Santos, Area Sales Manager and Market Responsible at Bosch Packaging Services, who visited the production site regularly. “During one of my service visits we discussed the machine capacity and the risk of longer downtimes due to defective or obsolete components and spare parts availability,” Dos Santos explains. Since both machines were still working at a satisfactory level at that time, Mondelēz decided to post-pone a possible exchange of the control units. “But things always seem to happen when you least expect them,” says Daniel Matthee.

Fast service support requiredIn spring 2013, Mondelēz experienced the worst case scenario: the control unit of the Sigpack HSM – the heart of the machine – reported a hardware error. The result was a machine failure, calling for the quickest possible solution. Bosch organized and implemented the required spare parts, which were not easy to find due to the age of the machine. “After installing the appropriate component, we felt time had come to replace all critical obsolete spare parts to ensure future production,” says Matthee. Together with Bosch, the Mondelēz project managers decided to modernize the central control units with their control cabinets and drives. They also seized the op-portunity to upgrade the Sapastoc storage unit with new steering components.


The Bosch specialists manufactured and programmed the components for both units within six months and deliv-ered them to South Africa at the beginning of December 2013. The main concern of the project team was to not disrupt production operations in Port Elizabeth. For this reason, they decided to implement the new components during the three-week Christmas break. “Time was critical for us, as we needed to start producing immediately in the New Year to supply customers and markets with their orders,” explains Daniel Matthee. “Although we had pre-produced a great amount of Cadbury chocolate bars, we required a smooth installation within the given timeframe.” Bosch sent a well-established team consist-ing of several technical specialists and software experts to the production site. Together with Mondelēz’ project planners, they installed the new components and recom-missioned the machines.

More than just a modernizationAfter completing the modernization, the horizontal flow wrapping machine is working reliably and to its full capac-ity again. In addition, the overhaul had further advantages:

Mondelēz South Africa now has a user-friendly Human Machine Interface (HMI), which allows the operators to save more recipes and formats in the database. But most importantly, the company can be sure they will not get into a similar situation again in the near future. In the un-likely event of a malfunction, the up-to-date components of the modernized Sigpack HSM can be easily replaced with suitable and readily available spare parts.“We are very pleased with Bosch and every project team member’s effort during the preparation and moderniza-tion, as well as with the overall result,” says Matthee. “Thanks to the close collaboration we managed this critical situation without major effects on our production. We now also have state-of-the-art machines in our facility that will continue to reliably package our chocolate bars with the accustomed Bosch quality.”


Carina Schurr

Phone: +41 58 674 63 32


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A flexible solution for Fido’s fresh treats

Award winning “toothpaste box” steals the spotlight

for doggie dental treat packaging

The saying “A dog is a man’s best friend” is becoming even more true as we look into the level of care and consideration owners have for the health of their four-legged companions. Amidst the aisles of dog treats, customers are finding an expanding variety of options to enhance their pet’s health. To keep up with the demands of enthusiastic pet owners, many brands have introduced various treats for dental health aid.

Big Heart Pet Brands, the pet food and treat company based in San Francisco, California, is well-known for its line of iconic Milk-Bone biscuit treats and for being a pioneer when it comes to animal care. The most recent example to hit market shelves in 2014 was the Milk-Bone Brushing Chew, a dog treat that “tastes like a treat and cleans like a toothbrush.” To ensure shelf differentiation, Milk-Bone and Big Heart Pet focused on the design of their new award-winning package.

Packaging innovation beyond the expectation“The goal was to have customers instantly associ-ate the products as beneficial to a dog’s dental health,” Paul Baker, senior manager projects, packaging R&D, Big Heart Pet, stated. “After careful consideration, we came up with the idea to create a package similar to a traditional toothpaste


carton, making it recognizable and different from the standard stand-up pouch.”Before being placed into the toothpaste box, Milk-Bone Brushing Chews are packaged in a sealed bag with a reclose feature to ensure freshness and maintain product quality. Big Heart Pet needed three different carton sizes and two pouch styles to accommodate different volumes of brushing chews. A doy-style pouch was needed to fit the smallest container while the two larger cartons would use a side-gusseted pouch.

Forming the bag The challenging requirements included applying a Velcro closure on the doy bag, running film with a pre-applied closure to form the side-gusseted stand-up bag and having the flexibility to cater to the three carton sizes and two bag styles. For the interior bag, Big Heart Pet researched multiple bagging equipment suppliers and ultimately chose Bosch for its packaging needs. Bosch’s reputation as a single source solutions provider for vari-ous packaging equipment ensured Big Heart Pet would get a quality solution.

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After listening to Big Heart Pet’s needs, Bosch recom-mended the SVI 2620 WR vertical bagger for its flexibility in handling a range of bag styles. Since Big Heart Pet wanted a unique reclosable bag, Bosch customized the SVI 2620 WR to adhere a Velcro zipper instead of the common string zipper, enhancing ease of use. “The level of service and machine quality we have seen from our experience with the company over the last 20 years made us feel very comfortable choosing Bosch,” said Baker. “The range of solutions and ability to customize and easily upgrade technologies will give us the flexibility to expand production as the brand grows, while meeting current business goals.”

Connecting the moving partsIn addition to selecting the VFFS bagger from Bosch, Big Heart Pet also chose Ishida Co, Ltd. for a multihead weigher and Kliklock Woodman for the toothpaste-like carton erecting and closing. The three companies collabo-rated at Bosch’s facility in New Richmond, Wisconsin, to design a line that would provide a continuous flow from start to finish. The intricate packaging design required precise dosing to prevent line stoppages and maximize uptime. Bosch

used its broad experience while collaborating with Ishida, meticulously testing and adjusting the multihead weigher and bagger. Big Heart Pet credited the level of service from Bosch’s project manager with ensuring a smooth and easy process for Big Heart Pet, as well as the service technicians who trained the operators. “The Bosch team was very thorough making sure the equipment was suited to fit our needs and training our team to use the new bagger to its greatest capacity,” said Baker. “Through the series of training and factory ac-ceptance testing, we were able to learn quite a bit about what to expect from the vertical bagger when it came to our product.” The new packaging for Milk-Bone Brushing Chews has been well received since the product launch in April 2014. In addition, the innovative packaging line design was recognized with PMMI’s Packaging Line of the Year award in November 2014. It’s a win-win for Fido and Big Heart Pet Brands.


Paul Garms

Phone: +1 715 246 6511



You always remember your first Love Heart and for many, these unforgettable sweets with embossed messages are an indelible part of childhood. Behind these and many other top-selling treats is Swizzels Matlow (Swizzels), a UK success story with an 80-year legacy of confectionery delight, with more than 550 employees and sales in excess of 90 million dollars not only in the UK and Europe, but all across the world.

Based at a picturesque, former textile factory in New Mills, Derbyshire, England, Swizzels knows the key to future success is reinvention of its popular ranges – and continued innovation for its production lines. In 2012 the company launched Squashies, an exciting new confec-tionery range where its favourite brands, Love Hearts, Drumsticks, New Refreshers, and Double Lollies, are transformed into delicious squashy gum formats.

Sweet smell of successLove Hearts manufacturer Swizzels Matlow fall head over heels

for new Bosch robotics

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Available in four pillow bag sizes ranging from 20 grams to 160 grams, the confectioner needed to ramp up produc-tion to meet growing demand. Enter the first packaging robot at New Mills in the form of a Bosch Packaging Technology Paloma D2 Top Loader. With a robust proven design and high efficiency, the Paloma uses three vision-guided high speed Delta robots to ensure impeccably packaged products at a reduced cost per pack. This new solution replaced a drop-load system, allowing up to three streams of product to arrive from the vertical bagger and be packed directly into display cases.

Best suited solutionAccording to Paul Harvey, head of operations at Swizzels, “Bosch made certain they understood our business needs and confirmed the Paloma was the best suited solution. Implementation on site was excellent – and we were up and running ahead of schedule.”Results were instant. The new Paloma robotic solution boosted output by 20 percent with the ability to package 360 bags per minute while also allowing a 24/7 operation instead of the previous 2-shift operation. As all pack sizes could be handled by the same machine, the Paloma also saved floor space – a precious commodity in Swizzels’ factory.Managing director at Swizzels, Jeremy Dee is impressed, “The new Bosch machine is fast and inspiring. It also assures output, which is important to us with this new fast-selling range.” The robotic solution was well accepted by its workforce who were excited to see the machine in operation. The move also showed Swizzels was investing in the company’s – and their – future.

Impressive resultMarc de Vries, sales director at Bosch Packaging Technol-ogy SA, agrees, “We are really happy to see such an im-

pressive result for Swizzels with this project. It’s a great demonstration of how companies can leverage robotic automation to meet demand and generate competitive advantage. While this is Swizzels’ first Delta robotic pack-aging solution, we are looking forward to developing our relationship and to helping them achieve further growth.”For the makers of perennial favourites Love Hearts, it seems the Bosch Delta robots are definitely the beginning of a strong and rewarding partnership.


Marc de Vries

Phone: +41 21 644 25 82


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Consumers want what they want, when they want it – and food manufacturers need equipment and technologies that help them adjust to market shifts quickly and ef-ficiently. For global consumer products giant Unilever, packaging flexibility is a top priority for maximizing productivity. Take for example one of its top selling food brands – Knorr. The Knorr factory in Sanguinetto, Italy, produces most of the brand’s global jelly bouillon and its high pro-ductivity has helped make it the production benchmark for Unilever1. To handle increasing demands for different pack styles and formats, the company needed to imple-ment more flexible case packing operations.“Just a few years ago we only needed a case packer with one standard format – but now we need to make changes to package specific and different formats for our customers,” says Carlo Forchia, Unilever’s project delivery engineer at the plant.To incorporate a flexible new case packaging solution, Unilever reached out to Bosch Packaging Technology.

Serving global taste budsThe reach of the Knorr product line is enormous; everyday around 320 million people around the world consume a Knorr product.2 The jelly bouillon produced at Sangui-netto uses a patented jelly technology to create a soup stock that melts naturally into dishes to enrich flavor3. Sanguinetto is the only plant in Italy that makes jelly bouil-lon, but also produces other Knorr savory foods. In addition to the Italian market the plant also supplies

an extensive international market, particularly the UK, Germany and South America.

Flexibility times threeIn 2011, Knorr installed its first Elematic 2000 Wrap-Around case packer from Bosch to complete its high-speed line. “Our relationship with Bosch dates back to when we became the first Unilever plant in Italy to purchase a Bosch machine for our lines,” Forchia notes. The facility was so pleased with the results that it has since added two more Elematic case packers – with the most recent addition installed in September 2013. As a result, Unilever has improved operational efficiency and is able to change formats quickly for its Knorr range. Today, Bosch equipment is used for two standard packag-ing lines and one high-speed line.The Elematic 2000 includes an inner hood and is designed to case pack smaller bundles. It handles pack styles from tray, to full wrap-around, to two-part, shelf-ready packaging. “The unit has the flexibility to accommodate multiple pack styles, including single- or double-stacking,” Forchia says. At the plant, the Elematic currently packs between 35 and 40 cases per minute, with the capability to increase that per-minute rate.

That’s a wrap!Bosch boosts flexibility for Unilever’s Knorr Product Line

1 Source: http://www.unilever.com/resource/search/index.aspx?Search=Sanguinetto

2 Source: http://www.knorr.com/article/detail/245640/brand-history3 Source: http://www.unilever.com/brands-in-action/detail/

Knorr/292018/


Format changeovers can be made quickly and require no tools. “The Bosch equipment design is clever; with quick and easy changeovers that take anywhere from 30 min-utes to one hour. It gives us the capability to produce new types of trays, so we can respond to marketing requests quickly,” says Forchia. Another bonus for the Sanguinetto plant has been smooth implementation and customization offered by Bosch. “Technicians arrived immediately and quickly solve any issues,” Forchia notes. More recently, a belt at the Sanguinetto site was worn as a result of using a different format. Bosch created a new belt with customized modifications to work more efficiently with Unilever’s format. “They truly problem-solve to come up with a solution that works,” he says. “It’s a great approach.”

Flexible packaging has been key for the success of Unilever’s Knorr brand. With the help of Bosch, it is able to keep pace with consumer demands without compro-mising quality.


Bernhard Vaihinger

Phone: +49 7151 7007 67


Events Pharma2015/2016

packazine | 25

Events Food 2015/2016

Events Pharma2015/2016

Date Event Location Branche

05.14. – 05.17.2015 Afro Packaging Cairo Food

05.23. – 05.25.2015 East Africa Trade Exhibition Dar-es-Salaam Food

06.09. – 06.12.2015 Fooma Japan Tokyo Food

06.10. – 06.12.2015 Tea & Coffee World Cup Ho Chi Minh City Food

06.16. – 06.19.2015 Expo Pack Mexico Mexico City Food

06.17. – 06.20.2015 Propak Asia Bangkok Food

06.23. – 06.26.2015 Fispal São Paulo Food

07.15. – 07.17.2015 Propak China Shanghai Food

07.21. – 07.26.2015 Filda Luanda Food

09.01. – 09.03.2015 Propak West Africa Lagos Food

09.12. – 09.17.2015 iba Munich Food

09.28. – 09.30.2015 Pack Expo Las Vegas General

09.29. – 10.01.2015 Fachpack Nuremberg General

09.30. – 10.03.2015 AllPack Indonesia Jakarta General

10.13. – 10.16.2015 Japan Pack Tokyo General

10.20. – 10.23.2015 Scanpack Gothenburg General

10.27. – 10.29.2015 Gulfood Manufacturing Dubai Food

11.27. – 11.30.2015 Addis Agrofood Addis Abeba Food

01.31. – 02.03.2016 ProSweets Cologne Food

DateEventLocationBranche

05.12. – 05.14.2015FCE Pharma São PauloPharma

05.17. – 05.20.2015CIPM ExhibitionQingdaoPharma

06.15. – 06.19.2015AchemaFrankfurtPharma

06.24. – 06.26.2015P-MEC ChinaShanghaiPharma

09.28. – 09.30.2015Pack ExpoLas VegasGeneral

09.29. – 10.01.2015FachpackNurembergGeneral

09.29. – 10.01.2015Maghreb PharmaOranPharma

09.30. – 10.03.2015AllPack IndonesiaJakartaGeneral

10.05. – 10.09.2015SupplySide WestLas VegasPharma

10.13. – 10.16.2015Japan PackTokyoGeneral

10.13. – 10.15.2015P-MEC WorldwideMadridPharma

10.20. – 10.23.2015ScanpackGothenburgGeneral

10.25. – 10.29.2015AAPS Annual MeetingOrlandoPharma

10.27. – 10.30.2015CIPM Autumn ChinaWuhanPharma

11.03. – 11.04.2015PDA Universe of Prefilled Syringes ViennaPharma

11.08. – 11.11.2015ISPE Annual Meeting PhiladelphiaPharma

11.24. – 11.27.2015PharmtechMoscowPharma

04.19. – 04.21.2016PowtechNuremburgPharma 11/22-11/25/10

(subject to alteration)

(subject to alteration)

food & confectionery · issue 2015 - webpackaging · 2017-05-26 · amul dairy | “the taste...

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