Food & Confectionery · Issue 2012 - Syntegon · 2019-07-23 · processing confectionery. The...

Food & Confectionery · Issue 2012

Frosta | Wavy bags liven up freezersGrupo Siro | Product portfolio expanded Löfbergs Lila | Fair trade in a bag

packazine

2 | packazine Table of contents | Editorial

www.boschpackaging.com [email protected]

News

Facts & Trends04 Ultrasonic technology | Riding the waves

Customers & Markets

Food & Confectionery07 Lorenz | Modern packaging methods – traditional pack styles

10 Frosta | Wavy bags liven up freezers

12 Grupo Siro | Product portfolio expanded

14 Bio-Nahrungsmittel | Flexibility with quality

17 Löfbergs Lila | Fair trade in a Bag

Events

19 Events 2012

CoverFrosta developed an unusual packaging

in form of the company logo for its new frozen soups.

07 12 14

Customer magazine of the Packaging Technology Product DivisionRobert Bosch GmbH

Editor in ChiefCentral MarketingJohanna Marquette, Christin Pönisch Telephone +41 (0)58 674 [email protected]

DesignCentral Marketing, Karin Schmückle

PhotosB.J.Y.L.D; CN-Photography; Otlinghaus Fotodesign; Bosch Packaging Technology

PublishingProduct 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.

Imprint

packazine

Table of contents

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Dear readers,

Looking back on last year, the international growth strategy of Bosch Packaging Technology has paid off. We were able to increase sales significantly, meaning we

have again grown faster than our relevant market. We are pleased about that development and are looking ahead very positively.

During the preceding years, besides strengthening our presence in the established markets, we have increased our international activities in the emerging markets, especially in India, Thailand and South Africa. We are particularly proud of more than ten years of history in China, where we started with 13 associates in 2001. Today, Bosch Packaging Technology employs a workforce of almost 400 in Hangzhou, in the province of Zhejiang. Additionally, a

second location in Chengdu, in the West of China, began production at the end of last year.

With regard to trade show activities, a major highlight last year was our presence at Interpack, the world’s largest packaging exhibition, which only takes place once every three years, in Dusseldorf, Germany. Bosch Packaging Technology took over an impressive 2000 square meters of floor space and presented itself as a full-range provider, from standard machines to complex processing and packaging systems for our customers in the food, confectionery and pharmaceutical industry. Our One Stop Shopping approach offers both flexibility and the reliability of a competent partner, from conception to commissioning.

In 2012, we also look forward to meeting you at our trade show stands. Whether it be at Achema in Frankfurt, Germany, Pack Expo in Chicago, USA, or another exhibition, please feel free to come and talk to us and discuss your present and future requirements and projects!

Yours,

Friedbert Klefenz

17

Friedbert KlefenzPresident,

Bosch Packaging Technology

Editorial

4 | packazine News Facts & Trends

Riding the wavesUltrasonic technology is a key to environmentally friendly and profitable production

Professor Dr Bernd Wilke, Head of Research and Development at Bosch Packaging Technology

According to a recent survey conducted by German market intelligence organiza-tions EHI and GS1 entitled ‚Trendstudie 2011: Verpackung und Produktschutz’ (2011 trend study: packaging and product protection), product safety is a key priority for both retailers and con-sumers when it comes to food packag-ing. The purpose of packaging is to pro-tect food products against contami-nants, harmful substances, oxygen and light and manufacturers have to comply with ever changing regulations and legal provisions. Increasingly, leading retailers around the world are working closely

with governing bodies and regulatory authorities such as the Food and Drug Administration (FDA). The aim of these retailers is to ensure that they are satisfying the standards covered by the Global Food Safety Initiative (GFSI), such as those associated with the British Retail Consortium (BRC), the I nternational Food Standards (IFS) and ISO 22 000.In addition to product safety, the drive towards sustainability is gaining major significance within the packaging industry. It becomes even more relevant when looking at the critical state of the

world’s food supply. Almost a billion people are currently suffering from starvation. A further billion people face insufficient food supplies, even though there is plenty available in many countries around the world. On average, a third of food produced is lost on its way from the field to the consumer. One reason for this is inadequate packaging, providing insufficient protection against external influences. Packaging saves more resources than it uses, since the greatest waste of resources results from the actual product becoming spoilt and inedible.

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With rising prices and heightened com-petition affecting manufacturers, there is an increasing drive to save resources and reduce costs through more efficient production processes. Packaging sys-tems with maximum overall equipment effectiveness (OEE) enable this optimal usage of resources.

Ultrasonic technology increases room for maneuverUltrasonic sealing technology is one possibility that enables manufacturers to reduce both costs and product waste while providing strong product protec-tion. Reduced energy consumption, material savings and increased equip-ment availability allow manufacturers to produce more sustainably and profit-able. In comparison to other sealing methods used to date, such as hot and cold sealing, ultrasonic technology represents an attractive alternative.

Reliable product protection – assured product qualityUltrasonic technology offers crucial benefits from a product safety perspec-

tive. The new technology avoids the risk of diminished seam quality and leakage due to contamination of the sealing area by using high frequency vibrations that remove product residues. The resulting sealed seams are secure, ensuring the product is tightly packaged. One drawback associated with the often-used hot sealing method is the negative influence on product quality by the required sealing heat. The high temperature of the sealing jaws can cause product damage: here ultrasonic’s “cold” approach is a major advantage. Since the tools used are cold, the sealed seam can be placed close to the product without having a negative impact on its quality. Manufacturers can further benefit from the fact that there is no risk of heat-related damage to materials or products in the event of machine stoppages. A popular alternative in the past, when packaging heat-sensitive products like chocolate, was to use cold sealing film to prevent products from melting. One disadvantage of this approach is the limited storage life of the film,

which tends to stick together or to the product. Furthermore, the relatively high costs involved with cold sealing film have encouraged manufacturers to consider alternative sealing methods like ultrasonic technology.

Saving resourcesUltrasonic sealing technology provides significant savings in terms of the energy required for the packaging process. The film is not heated from the outside inwards, but as a result of molecular vibration within the film. As such, the temperature needed for welding purposes is generated inside the film in the actual sealed seams. This means, for example, a horizontal flow wrapping machine requires only 4.0 joules for sealing compared to hot sealing with 6.7 joules. As a further benefit, savings can be made with material costs. For horizontal packaging applications, manufacturers can use less expensive film materials, replacing the kinds of films previously required for hot sealing with thinner and more cost-effective alternatives. In addition, the narrower sealed seams possible with ultrasonic sealing technol-ogy reduce the amount of material needed. With vertical form, fill and seal machines, up to 16 millimeters of film can be saved per package in terms of bag length. The “cold” ultrasonic sealing technology also eliminates the need to clean hot sealing jaws. By reducing the issue of film sticking to the heated jaws, ultrasonic technology ensures that there is less material residue after sealing and fewer defective packages, all of which can help to reduce equipment down-time. As a result, manufacturers can see significantly increased operating times and a reduction in waste material.

Flexibility for manufacturers Ultrasonic sealing technology from Bosch Packaging Technology is currently

6 | packazine News Facts & Trends

processing confectionery. The technol-ogy is ideally suitable for difficult cutting applications such as sensitive, sticky, laminated or layered products like bars, cakes and pet food. It is used to cut across strands of product, dividing them into individual sections or segments. The use of high-frequency vibrations enables clean cuts and produces smooth surfaces. Product quality remains high due to the low levels of tension and pressure applied. One current ultrasonic cutting applica-tion from the Bosch portfolio is the WRQ 0400 US ultrasonic cross-cutter for bar production.

The lesson is clearFood manufacturers play a crucial role in the global effort to save resources and avoid food waste. They can make an important contribution by using effective and progressive production equipment and processes. With its

innovative technology, Bosch Packaging Technology supports improving the current situation in terms of resource saving. Ultrasonic sealing is a key part in this initiative and Bosch is continuing to develop this technology to expand the range of possible applications.Ultrasonic technology is more than a contribution to an environmentally friendly and profitable production. It will also play an important role in the future for process safety, since ultrasonic sealing can be used to validate the packaging process. Given the increas-ingly stringent regulations imposed on the food industry, this may become an important consideration for food manufacturers as well.

For more information please contact:

Prof Dr Bernd Wilke

Phone: +49 711 811 57813

E-mail: [email protected]

available for long- and cross-sealing stations on its horizontal flow wrap-ping and vertical form, fill and seal machines. Examples of horizontal flow wrappers for ultrasonic sealing are the Sigpack HCUR, the Sigpack HCUL and the Miniwrap BVK 2000 UA, which use, respectively, rotary and long dwell cross-sealing stations. Bosch also offers vertical form, fill and seal machines incorporating ultrasonic sealing technol-ogy. Two examples are the SVE 3615 LR with cross and long sealing and the SVE 2520 AR using ultrasonic technology for cross sealing. The typical pack styles produced on these types of equipment are block-bottom, pillow, gusseted and doy-style bags. With horizontal bag types, ultrasonic can be used for both single packs and multipacks.

Ultrasonic technology in processing Not only can ultrasonic technology be used as a sealing method, but also for

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One-stop primary and secondary packaging solution for NicNac’s from Lorenz Snack-World

Lorenz Snack-World, a German snack producer based near Frankfurt, has produced some world famous brands for several decades. These include the highly-popular NicNac’s, Chipsletten, Crunchips and Saltletts snacks. As packaging plays an important part in consumer purchasing decisions, Lorenz favors efficient packaging methods for its products that combine traditional pack styles with a high recognition value. This certainly applies to NicNac’s, the undisputed original nut snack with a crunchy coating and the first monobrand on the snack market.

Recently, the company looked for a new, flexible system with a small footprint for packaging NicNac’s, which had to be capable of high output levels as well as gentle product handling. Following a successful project in 2009, the company again decided to turn to Bosch Packaging Technology for a solution. Bosch was able to meet all of Lorenz’s expectations and delivered an integrated system for primary and secondary pack-aging, utilizing expertise from across different Bosch sites. Lorenz profited from Bosch’s One Stop Shopping concept by designing a more efficient

packaging process and concentrating on its core competencies in the snacks business. The newly integrated packag-ing line combines the SVE 2510 AT Twin version vertical flow wrapper for primary packaging with the Elematic 3000 S for secondary packaging.

Fast and flexible primary packagingWith limited production space available, the SVE 2510 AT Twin version met the selection criteria for the primary packag-ing system of delivering a high output while occupying a small footprint. The machine produces 100 block-bottom

Modern packaging methods for traditional pack styles

8 | packazine Customers & Markets Food and Confectionery

bags per minute with filling levels of 125 grams. Additionally, the line should offer the flexibility to produce XXL pillow bags with a filling level of 250 grams. The SVE 2510 AT Twin version also fulfills this requirement with an output of 60 bags per minute.Consisting of two machines, the SVE Twin version can be operated via separate touchscreens. This provides Lorenz with a flexible and low-disruption production process for the NicNac’s, as if one machine is out of operation the second continues to run and thus avoids a complete shutdown of production.Another advantage of the Bosch system is that placement of the control cabinet is independent of the machine location, which allows for a flexible and optimized utilization of the production space. Lorenz has had the cabinet installed on the multi-head weigher platform,

which does not affect the production area and reduces the line’s overall footprint. Thanks to this “slim” machine concept, the SVE is an ideal solution for economic, low-cost production and its open and compact design also allows for easy operation and maintenance.

Attractive, shelf-ready packaging for snacksA particular challenge in the secondary packaging of NicNac’s was to place the bags, which are difficult to package, into the carton at high speeds, while ensuring gentle handling. The challenge came from the nature of block-bottom bags, which are flexible and therefore difficult to group. Unlike piece goods, the NicNac’s bags can neither be accu-mulated nor stacked. However, Bosch’s innovative Elematic 3000 S offered the perfect solution. Mr Joachim Jeremias,

Production and Engineering Manager at Lorenz Nuss GmbH, says, “Bosch’s long-term experience in secondary packaging convinced us that we had a reliable partner on our side for the successful realization of our project.”From the flow wrapper, the block-bottom bags are transported lying down via two lanes towards the Elematic 3000 S at a speed of 100 bags per minute for each lane. Bosch developed a special, modular grouping system, which consists of an infeed belt, acceleration belt, dual-tension unit, push-off from dual-tension unit and buffer station, and an accumulation area in front of and push-off onto the lifting table. The special grouping system, including storage areas, ensures that the various product streams can be balanced.Traditionally, bags are packaged lying down. However, in order to achieve

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the best on-shelf display, the special NicNac’s block-bottom bags are pack-aged and presented standing up. A wrap-around lowering method of the Bosch line ensures a gentle, compact packaging of the bags to create a shelf-ready package, which consists of a display tray with a slip-on cover. Due to its dual-level technology, the Elematic 3000 S Twin achieves a very high output rate with a comparatively small footprint.

Productivity along the lineThe objective was to retain the traditional primary and secondary packaging for NicNac’s, while boosting output levels. This was achieved via the Twin version of the grouping station of the Elematic 3000 S. As a result, the packaging line for NicNac’s has fewer unscheduled downtimes and

therefore achieves higher productivity.Working together with a single supplier for the entire packaging line means that Lorenz can get any line-related issues quickly resolved. Bosch’s high level of technical expertise is immediately available, which avoids unnecessary downtime and production stoppages. This enabled Lorenz not only to achieve a seamless integration of on-site equipment, but also to have a smooth production process delivered through the coordinated portfolio from Bosch.

Pursuing core competenciesToday, Lorenz is profiting from Bosch’s One Stop Shopping concept because it can concentrate on its core competen-cies without having to worry about improvements to the packaging process or the integration of single machines.

Mr Jeremias is delighted with Bosch’s ability to deliver high output on a small footprint, “Now we can concentrate on developing new products and operate with increased efficiency at the same time. We are very satisfied with the project and are grateful for the expertise contributed by Bosch in order to satisfy our particular requirements.” For more information please contact:

Nicole Puschina

Phone: +49 7151 7007 97



Wave as model for new packagingThey were on display right on time for the launch in October 2011: Frosta’s new frozen soups. Up to this point, customers only had the choice between either canned or powdery instant soups. The frozen soups developed by Frosta contain crisp vegetables and more vitamins due to gentle production. Their freshness is underlined by an attractive look.

While they were searching for a special packaging solution, the company logo soon struck the eye of the designers. The Frosta wave serves as a model for the new packaging. “Our brand manager Hinnerk Ehlers was very enthusiastic about this idea. It seizes on the proven frozen food packaging and at the same time catches attention through its innovative form. Thanks to the wave shape, we create an additional con-

nection to our brand,” says Ralf Finck, head of Frosta’s Packaging Development Department.

Flexible machines for new pack styleFrosta faced two challenges at the same time: the development of an entirely new frozen product, and the realization of the unconventional packaging concept. For Frosta, sustainable use of resources is of top priority. Therefore, a replacement

Frosta’s wavy bags liven up freezersFrosta has developed an unusual packaging for the market launch of its new frozen soups

in form of the company logo. Prerequisites were resource and cost savings. In close

cooperation with Bosch Packaging Services, it took Frosta only half a year to successfully

modify its existing packaging machines.

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and Bosch started working on technical implementation. “There was no solution in the market for this type of packaging. This was also new ground for us at Bosch,” says Werner Ruhmann, Sales Director Germany at Bosch Packaging Services. “We analyzed the packaging concept and developed a suitable format set at our production plant. We then tested and optimized the format parts on our own machines before transferring them to Frosta’s machine park,” Ruhmann explains.Thanks to the fast and smooth develop-ment work, the date for market launch in October 20011 was complied with. “Owing to the professional development work and the close partnership, our joint development project only took half a year. At the end of September we produced the first new wave bags in Bremerhaven,” Finck confirms. In the

first shift, Frosta packed as many as 40 000 soups in three different flavours into the new wave-style bags.

Success all along the line“The new bag format reflects the inno-vative nature of our new product. At the same time, it maintains the established handling for our customers. We also had to ensure that the product can be at-tractively positioned on the shop floor,” explains Torsten Matthias, Marketing Manager at Frosta. There is a further major advantage to the new packaging style: The frozen soups now take up an entire row in the freezer, because no other packaging styles can be mixed with the wavy format.“Our project was a great success all along the line,” confirms Ralf Finck. “Thanks to the flexibility of the Bosch machines and the customer-oriented work of the Bosch service team, we were able to realize our project in next to no time.” The two companies con-tinue working on further optimization of the packaging. So nothing prevents an adaption to further products in the future. Meanwhile, Frosta has patented its wavy bag to prevent imitations.


Werner Ruhmann

Phone: +49 151 168 05 471


of the machinery park was out of ques-tion. The existing equipment had to be upgraded for the new wavy bag.The vertical form, fill and seal machine SVK 3600 L seemed especially suited for modernization. Frosta already produces on machines from Bosch since the mid-seventies. “We needed a reliable partner whose machines were so flexible that they could also be used for the implementation of new packag-ing styles. The SVK machines meet all technical requirements. Moreover, the team from Bosch Packaging Services was very energetic and committed to finding the best possible solution for us,” Ralf Finck emphasizes.

Partnership for packagingAs soon as the product development department gave its approval for the packaging style in March 2011, Frosta

Packaged in the shape of the company logo – for the market launch of its new frozen soups, Frosta developed an unusual packaging concept.


Grupo Siro is renowned across Spain for its pasta, bread, biscuits and other baked goods. The company is one of the largest in the Spanish food industry. Its success story began in 1918, with the establishment of a family-run business called Galletas Siro SA. Today, Grupo Siro has around 3600 employees at 16 locations across Spain. Since 1991, its turnover has increased by a factor of forty. One of the secrets of this success is the intensive food research that Grupo Siro conducts, making it one of the most innovative companies in its sector. Social responsibility is also an integral part of its corporate philosophy; in 2010 the group was rated as one of the five best employers in the Spanish food industry.

Juan Manuel Gonzáles Serna and Lucia Urbán Lopez, the company’s owners, have continuously expanded its product range over the past 20 years and have invested in state-of-the-art production lines. As a result, Grupo Siro offers its customers a wide variety of high-quality products in several price ranges. In 2011, the company decided to extend its product portfolio even further and started production of six types of cereal bars, which are enjoying increasing popularity.

All-in-one solution from BoschFor Luis Manuel Sanz, project engineer at Grupo Siro, entering the new field of bar production provided a major chal-

lenge. From the beginning, Sanz favored an all-in-one solution, to cover both the production and packaging of bars. As Sanz explains, “It was important for us to fully concentrate on exploiting the new business field. In order to reduce the technical complexity of the project, we were looking for a one-stop provider right from the start.” Not only were the production and packaging lines supplied by Bosch, but the experts at the testing plant, or “Technikum”, at the Bosch site in Viersen, Germany, assisted in the devel-opment of the bars themselves. Here, six different bars were created and tested under real production conditions. The results were convincing and pro-

Grupo Siro expands product portfolio

The spanish company exploits a new business field with a modern bar production line from Bosch.

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Flexible and efficient conceptAs the new line needs to produce and package six different sorts of bars, Grupo Siro placed great importance on fast changeover times and easy clean-ing. The production line from Bosch fulfills these requirements, ensuring efficient and hygienic processes. The blender with an integrated cleaning-in-place system (CIP), even allows auto-matic cleaning to take place without affecting the ongoing production. Addi-tionally, an integrated washing system continuously cleans the conveyor belt. Luis Manuel Sanz is very impressed by the excellent working relationships and cooperation fostered between Grupo Siro and Bosch. During the whole course of the mutual project, the

pelled Grupo Siro’s successful entry into the new market segment.

Bundled know-howFor a comprehensive realization of the customer’s specific requirements, Bosch combined technical expertise and solutions from across a number of its facilities. The Bosch site in Viersen supplied the bar production line, which consisted of dosing and dissolving units, a batch cooker for producing the binding agent, plus the forming line for the bar mass. The binding agent and cereals are mixed in a blender and then rolled out flat on a conveyor. After passing a cooling tun-nel, the slab is first cut longitudinally and fanned out, before a cross cutter separates the individual sections into bars. The system can produce up to 500 bars per minute. The finished products are individually packaged on a Pack 401 horizontal flow wrapper, manufactured in Schiedam, Netherlands. And finally, a Presto D2 Delta robot, from Romanel-sur-Laus-anne, Switzerland, places the wrapped bars into display cartons. The machines for erecting and closing the display cartons were also supplied by Bosch.

Spanish agency IMCO and the responsi-ble Project Managers Andreas Miguel and Jörg Schongen from Bosch main-tained continuous contact with Grupo Siro. This was certainly one of the reasons for the rapid project implemen-tation and smooth integration of the line into existing processes. After only five months, the new line went into production and in November 2011, the first bars rolled off the line. Grupo Siro has now arrived in the cereal bar business and Spanish consumers can enjoy six new delicious products.


Frank Jansen

Phone: +49 2162 248 452



Founded in 1979, the company Bio-Nah-rungsmittel can be considered a trend-setter, having provided a range of healthy and natural products since its founda-tion, long before the idea of organic food and well-being became popular. Based in Grödig near Salzburg, Austria, they import and package organic food such as dried fruit, nuts, fruit and nut mixtures, snacks, seeds and grains as well as cere-als. The company also offers contract packaging for large retailers.To provide the best quality products to its customers, Bio-Nahrungsmittel obtains its raw products only from certi-fied organic cultivation. This rigorous attention to quality, combined with the use of modern packaging technology,

makes the company a leading player in the European organic food trade. The 80 employees are responsible for the rapid handling of orders from whole-salers, supermarkets and drug stores in Germany, France, the UK, and other European countries.

New pack style for on-shelf differentiationOver the last 30 years, Bio-Nahrungsmit-tel’s packaging methods have changed considerably as has the volume of pro-duction. They now produce approxi-mately 24 to 25 million bags per year with a filling volume of 100 to 1000 grams each. Today, the company’s name stands for top-quality products, flexibility

and high output capacity. To further meet these requirements and also the expectations of its retailer and whole-saler clients, Bio-Nahrungsmittel needs a reliable equipment partner with advanced and flexible machines. With Bosch Packaging Technology, Bio- Nahrungsmittel found such a partner.Bio-Nahrungsmittel has used Bosch equipment since the 1980s, starting with an intermittent vertical form, fill and seal machine to package nuts. To date, the company is using seven machines from Bosch for its packaging processes and continues to explore new packaging options. Recently, Bio-Nahrungsmittel wanted to add a reclosable doy-style bag to its product portfolio. The new pack

From flexibility to quality – It’s in the bagHigh flexibility is key for Bio-Nahrungsmittel to meet changing consumer demands quickly

The intermittent vertical bagger SVI 2620 offers the ultimate in flexibility with retrofitting options to produce a wide variety of bag styles. Changeover between full corner seal and doy-style bags can be even more quickly realized by exchanging the format set and turning the existing cross-seal housing by 90 degrees.

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style guarantees a premium look and offers on-shelf differentiation. However, its existing, standard vertical form, fill and seal machines were not capable of handling the change. To incorporate the new pack style and meet its flexibility, quality and output requirements, Bosch Packaging Technology provided the solution.

Keeping its options openBio-Nahrungsmittel’s needs were quite specific. While output needs to be high, this was not the major focus. As a premium provider of organic products, the company emphasizes quality – it must deliver best-in-class products to the retailers it serves. Additionally, consumer demands tend to change quite rapidly, challenging Bio-Nahrungsmittel to incorporate flexibility

into its lines. There are periods where consumers prefer nuts and other times when dried fruits are all the rage. Prefer-ences of retailers and wholesalers regarding product presentation also con-tinuously change. In order to adapt to fluctuating demands, Bio-Nahrungsmittel needs flexible machines that allow rapid – or in the best case immediate – changeover of products and pack styles on its lines. The company was not only seeking to add a reclosable doy-style bag to its offering, but it also wanted the flexibility to handle a variety of bag sizes and styles without slowing down the line. Therefore, easy machine changeover was essential. To meet the needs of Bio-Nahrungs-mittel, Bosch provided the intermittent vertical bagger SVI 2620. The SVI 2620 offers the ultimate in flexibility with

retrofitting options to produce a wide variety of bag styles, including pillow, side gusseted, block-bottom, corner seal and doy-style bags with optional reclo-sure. This allows Bio-Nahrungsmittel to handle current and future pack style needs to continually differentiate its products at the point-of-sale. A key feature of the SVI 2620 is easy changeover. To change between pillow, gusseted and block-bottom bags, the operator simply changes the format set with minimal downtime, for overall equipment efficiency savings. This is also the case when switching to full corner seal bags, where the format set is changed and a corner sealing unit is added. As Bio-Nahrungsmittel’s machine is retrofitted for doy-style bags, change-over between full corner seal and doy-style bags can be even more quickly


realized by exchanging the format set and turning the existing cross-seal hous-ing by 90 degrees. In the future, if the company decides to change the format sizes of its corner-sealed or doy-style bags, it will simply have to acquire the corresponding format set as the existing sealing unit can be further used.

Sealing-in qualityUsing the intermittent SVI 2620 machine enables Bio-Nahrungsmittel to package its products in high quality bags with secure seals resulting from long sealing times. Plus, the reclosure on its doy-style bags will lock-in freshness for a competi-tive advantage with consumers. All of this was made possible by the SVI 2620. Additionally, high process reliability is essential for delicate snack products and

Bosch’s SVI ensures this through its robust design. Christian Winzer, Managing Director of Bio-Nahrungsmittel, delighted with the relationship with Bosch, states, “No other packaging machine supplier was able to meet our need for rapid change-over and flexibility to the extent that Bosch could. The SVI 2620 allows the easiest changeover I have experienced and ensures that we as a supplier are able to respond to changing consumer demands and bring a consistently high-quality package to our customers.”


Robert van Mol

Phone: +31 435 574 027


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Consumers are increasingly aware of the impact of their food and drink choices, demanding environmentally and socially friendly options such as organic and fair trade products. As a result, many Euro-pean countries have experienced signifi-cant growth in fair trade coffee sales which is one of the fastest growing sec-tors in the region’s coffee market.1

More and more food and beverage manu-facturers are increasing their commit-

ment to producing and importing sus-tainable fair trade and certified products including the Swedish family-owned company Löfbergs Lila. With headquarters in Karlstad, Sweden, Löfbergs Lila is one of the largest coffee importers and roasters in Europe. Cur-rently, 30 percent of Löfbergs Lila’s cof-fee production is certified and the com-pany is aiming to have all of its products meet this certification by 2015.

Although a prominent coffee producer in Europe, a recent major order of whole coffee bean bags challenged the company’s capabilities, requiring an increase in production volume as well as a switch from its existing ground coffee packaging line. In an effort to optimize production flexibility and weight precision, Löfbergs Lila turned to Bosch Packaging Technology.

A complex problem....When seeking a new line to produce whole bean bags to fulfill the new order, a key concern of Löfbergs Lila’s was the ability to maintain its strong brand iden-tity. Moreover, the coffee producer needed a precise system that could guar-antee that all bags were filled to the appropriate level and weight ensuring cost savings and efficient production. Additionally, only limited floor space was available. These challenges highlighted the need for a tailored production line with a small footprint.

...with a complete solutionThe installed equipment is based on Bosch’s Module++ concept, a modular approach to packaging line design. Bosch delivered the line fully integrated with all packaging components from the dosing and gassing unit to the valve applicator. It includes a number of modu-lar Bosch machines such as the net-weigher FIW 4021 GK, vertical bagger

Löfbergs Lila partners with Bosch Packaging Technology to meet

changing production demands for fair trade coffee

Fair trade in a bag

1 Lewin, B., Giovannucci, D. & Varangis, P. 2004. Coffee Markets. New Paradigms in Global Supply and Demand. The World Bank. Washington.


PME 4001, checkweigher KWI 5000, the Delta robot Paloma D2 as well as the valve applicator CVA 2000 VIS for inter-nal valves. Through the net-weigher, the coffee beans are filled into the bags formed by the vertical bagger, while the valves are applied to the inside of the packaging material. After a final check, carried out by the checkweigher, the bags are transported via the conveyor to the Delta robot that picks and places the bags in cartons.

The right choiceEach component in the Bosch line was selected according to Löfbergs Lila’s needs. The modular concept of the flexi-ble vertical bagger PME 4001 for pre-

mium bags allows for easy retrofit and high bag-style flexibility at small foot-print. Good access to format parts accel-erates changeovers and maintenance. The Delta robot Paloma D2 aligns the filled bags and places them into trays and shipping cartons. Depending on the size and type of product, the robot allows a pick and place movement of up to 240 products per minute for high levels of productivity. Currently the new production line is packaging both regular and certified Löfbergs Lila whole coffee beans in one kilogram bags with an out-put of 60 bags per minute. Due to the fact that Löfbergs Lila pack-ages high-value coffee, weight precision was also a key parameter in the choice of

equipment to avoid under- or over-filling. To ensure all bags are filled with the right amount of whole coffee beans, Bosch designed its advanced weighing solutions into the line. The FIW 4021 GK net-weigher operates with a two-stage weighing process. In the first stage, the product is pre-weighed with a strain-gauge weighing cell. In the second stage, a further filling takes place and the final weight is determined with a high-preci-sion compensation weighing cell. The system allows for the accurate filling of Löfbergs Lila’s whole coffee bean bags ensuring the appropriate weight of the end product. The integrated check-weigher in the line, the KWI 5000, offers high levels of precision for both small and big products measuring the weight of each package with high accuracy.

Successful partnershipAs the demand for certified and fair trade products increases, Löfbergs Lila expects to grow as a company commit-ted to sustainable trade and the produc-tion of high quality coffee. Thanks to Bosch’s integrated packaging line and support, the company is ready to handle larger orders due to the flexible systems which ensure cost-effectiveness in the long-term through high levels of preci-sion.


Michael Voeth

Phone: +49 711 811 57595


packazine | 1919 | packazine Events 2012

Headlineauch mehrzeilig

Lead

Events Food 2012

Events Pharma2012

Date Event Location Branch

06.05. – 06.08.2012 FOOMA Japan Tokyo Food

06.12. – 06.15.2012 Fispal São Paulo General

06.13. – 06.16.2012 ProPak Asia Bangkok General

06.26. – 06.29.2012 EXPO PACK Mexico Mexico City General

07.18. – 07.20.2012 ProPak China Shanghai Food

08.24. – 08.26.2012 China Dairy Industry Show Hangzhou Food

09.06. – 09.09.2012 IPACK Istanbul Istanbul Food

09.11. – 09.13.2012 International FoodTec India Mumbai Food

09.25. – 09.27.2012 Fachpack Nuremberg General

09.26. – 09.27.2012 Empack Brussels Food

10.08. – 10.11.2012 Taropak Posen General

10.08. – 10.12.2012 Agroprodmash Moscow Food

10.23. – 10.26.2012 Scanpack Gothenburg Food

10.28. – 10.31.2012 PackExpo International Chicago General

11.19. – 11.22.2012 Emballage Paris General

11.21. – 11.24.2012 Allpack Indonesia Jakarta General

12.07. – 12.10.2012 PackPlus New Delhi General

DateEventLocationBranch

05.29. – 05.31.2012FCE Pharma Int. São PauloPharma

06.13. – 06.16.2012ProPak AsiaBangkokGeneral

06.18. – 06.22.2012AchemaFrankfurt am MainPharma

06.26. – 06.28.2012CPHI, P-Mec ChinaShanghaiPharma

06.27. – 06.29.2012INTERPHEX JAPANTokyoPharma

09.24. – 09.27.2012China PharmBeijingPharma

09.25. – 09.27.2012FachpackNurembergGeneral

10.04. – 10.05.2012INTERPHEX PUERTO RICOSan JuanPharma

10.14. – 10.18.2012AAPS Annual MeetingChicagoPharma

10.23. – 10.25.2012A3P CongressBiarritzPharma

10.28. – 10.31.2012PackExpo InternationalChicagoGeneral

11.11. – 11.14.2012ISPE Annual MeetingSan FranciscoPharma

11.19. – 11.22.2012EmballageParisGeneral

11.21. – 11.23.2012CPHI, P-Mec IndiaMumbaiPharma

11.21. – 11.24.2012Allpack IndonesiaJakartaGeneral

11.26. – 11.29.2012PharmTechMoscowPharma 11/22-11/25/10

Food & Confectionery · Issue 2012 - Syntegon · 2019-07-23 · processing confectionery. The...

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