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
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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con ea facincil del estrud
ea at et dolore dunt ali-
quat. Nos et augait irilla
feuguer ip er si.
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la faciliquat.
High speed wrapper
Flexible Toplader arm
Section of the system
Multi pack
8 | packazine Customers & Markets Food and Confectionery
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!
For more information please contact:
Urs Schweizer
Phone +41 52 674 6541
packazine | 9
bosch_key_visual_e.indd 1 14.2.2008 14:51:59 Uhr
10 | packazine Customers & Markets Food and Confectionery
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!
For more information please contact:
Martin Kühl
Phone +49 711 811 57480
1
12 | packazine Customers & Markets Food and Confectionery
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…
For more information please contact:
Oscar Gomes
Phone +33 388 20 97 84
1 2 3
14 | packazine Customers & Markets Food and Confectionery
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.
For more information please contact:
Uwe Pfander
Phone +49 711 811 57 478
16 | packazine Customers & Markets Food and Confectionery
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.
For more information please contact:
Maggie Zhou
Phone +86 571 8726 5008
High performance SVE 2510 LR:
Continuous bag forming, filling
and sealing machine
18 | packazine Customers & Markets Food and Confectionery
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.
For more information please contact:
Marco Kohler
Phone +41 52 674 74 73
1 2
20 | packazine Customers & Markets Food and Confectionery
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.
For more information please contact:
Cees Coppens
Phone +31 495 574 338
22 | packazine Customers & Markets Food and Confectionery
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.
For more information please contact:
Marc de Vries
Phone +31 10 488 5753
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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