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Food & Confectionery · Issue 2014

Solberg & Hansen | Coffee roaster ramps up for successWildlife Sciences | Packaging that’s not “for the birds” Harada | Rusks gently and efficiently packaged

packazine

www.boschpackaging.com [email protected]

2 | packazine Table of contents | Editorial

News

Facts & Trends04 Efficiency and flexibility | Banking on biscuits

Customers & Markets

Food & Confectionery07 Kärntnermilch | Flexibility in the dairy industry

10 Wildlife Sciences | Packaging that’s not “for the birds”

12 Solberg & Hansen | Coffee roaster ramps up for success

14 Essen Production | Tea Time, Sweets Time

17 Harada | Rusks gently and efficiently packaged

20 Mondelēz Ireland | Treating root causes instead of symptoms

Events

23 Events 2014/2015

CoverThe addition of a vertical packaging line

from Bosch boosts productivity of Norwegian premium coffee roaster by 40 percent.

07 10

Customer magazine of the Packaging Technology Division,Robert Bosch GmbH

Editorial teamCentral MarketingChristin Pönisch (Head),Annette Soyke, Vanessa LonkenPhone +49 711 811 [email protected]

DesignCentral Marketing, Karin Schmückle

PhotosB.J.Y.L.D; CN-Photography; raff media group gmbh; Kati Molin ( Fotolia.com); Bosch Packaging Technology; Allergy Laboratories, Inc.; Harada Ltd.; Mondelēz Ireland; Novartis; Serum Institute of India; Siemens & Co.

PublishingBoard of ManagementStuttgarter Straße 130 D-71332 Waiblingen

© Copyright · Packaging Technology Division, Robert Bosch GmbH

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

Imprint

packazine

Table of contents

Dear readers,

This year, the focus of all our efforts at Bosch Packaging Technology is on Interpack 2014, the world’s biggest packaging technology trade fair. Back at the very first Interpack in 1958, the former companies Hamac Packmaschinen and Hansella-Maschinen (later Hamac-Hansella), Hesser, Höller,

Magrolo-Maschinen (later Makat), Sapal and SIG’s packaging sector (later SIG pack) from the food and confectionery sector as well as the pharmaceutical packaging machinery manufacturers Höfliger & Karg and Strunck presented their machines. These companies today have become part of the Bosch family, making Bosch Packaging Technology unite more than 150 years of packaging know-how under one umbrella. We will keep with the tradition of Interpack participation this year, too, by using the show as a platform to pre-sent you our latest innovations and proven portfolio on almost 3000 square meters of booth space.

The entire packaging machinery industry is in a time of change, the defining trends of which are still ever stricter regulations on production hygiene, constantly changing consumer requirements, and the imperative to cut costs. We at Bosch Packaging Technology are determined not simply to react to these changes, but to play an active part in shaping them.As we work to develop our innovations, we always have your needs as a producer in mind. Come to Interpack and be inspired by the equipment that Bosch can offer, which will give you the flexibility to react quickly to changes in the marketplace and help you to meet hygiene regulations. Our equip-ment is designed to support fast changeover times, quick and thorough cleaning, and simple opera-tion – all of which increases the efficiency of your production process. In addition, we are there to provide you with advice and tailor the best solution for your specific requirements: That might involve an upgrade to existing machinery, partial automation of your production line or it could mean a complete, seamlessly integrated system, that covers not just the production of bars, say, but also primary, secondary, and end-of-line packaging. We are also there for you once your equipment is in operation, offering you a range of services that includes everything from maintenance to training.Our 2013 financial results show that we are on the right track with this strategy. I would like to take this opportunity to thank you, our customers, for these excellent results. It is the trust that you continue to put in us, along with the ideas that emerge from our everyday work together, that motivate us and spur us on to be innovative. The success stories gathered here in the 2014 packazine will give you a taste of the successful collaboration. Yogurt, cookies, lozenges or vaccines – Packaged as promised. Bosch.

I hope you enjoy reading the new packazine.

Friedbert Klefenz

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14 17

Friedbert KlefenzPresident,

Bosch Packaging Technology

Editorial

Banking on biscuits: rising demand opens up new opportunities for food manufacturers

You might call it a global demand for small treats: The market demand for biscuits and savory crackers is on the rise, creating opportunities for food manufacturers to develop and strengthen their brands. According to Global Industry Analysts, the global bakery market is projected to reach US$ 410 billion in annual revenue by 2015 with the biggest growth for crackers and plain biscuits.1 From a

packaging standpoint, the growth in this market is boosting the demand for fully automated systems that increase efficiency and enable more hygienic processing. In addition, flexible equip-ment and tailored solutions, backed by expert support, will help manufacturers leverage the market opportunity in baked goods and meet ever-changing and diverse consumer needs.

Key mission: automation and flexibility A high degree of reliable and flexible packaging automation will be important for manufacturers to meet the growing demand for biscuits. Equipment needs to be designed for high-quality output to

1 Source: First Research – Cookie & Cracker Manufacturing Industry Profile (9/23/2013). http://www.firstresearch.com/Industry-Research/Cookie-and-Cracker-Manufacturing.html

4 | packazine News Facts & Trends

meet current and future requirements; at the same time, it needs to be easy to use and service. In addition, high overall equipment effectiveness (OEE) contin-ues to be an important factor in pur-chasing decisions.For a commodity like biscuits, efficient automated technologies with high-capacity process lines can compensate for low profit margins. In manufacturing facilities, where space is also a premium, high-speed automated lines enable greater productivity within an overall reduced footprint. With no two manu-facturers having the same needs, it’s crucial to work with a supplier capable of providing a packaging system custom-made to meet specific needs. Bosch Packaging Technology collaborates with customers to ensure that an appropri-ate, tailor-made solution is incorporated to achieve production goals and busi-ness objectives. As a rule, automated packaging lines need fewer operators compared to semi-

automated lines. It reduces the cost of labor and allows manufacturers to redi-rect workers to other important tasks as skills become more refined. New auto-mated lines also come with an advanced Human Machine Interface (HMI) that is easy and intuitive to use, reducing the time required for training. Over the past few years, Bosch Packaging Technology has been implementing such operator-friendly technology for the growing biscuit market with manufacturers see-ing successful results.As manufacturers often need to process different products on the same line, packaging systems flexibility is key to handle different pack styles and configu-rations for biscuits. Currently, 75 percent of biscuits are packed in flexible pack-ages. Typically, pile packaging is used for formats less than 50 grams, and both pile and slug formats are used for pack-ages between 51 grams and 100 grams. For packages over 100 grams, the vast majority are packaged into slugs.

With such growth predicted across the globe, consumer tastes are also becom-ing more versatile. Therefore, incorpo-rating automated packaging technology designed for maximum flexibility enables manufacturers to make quick and easy adjustments to respond rapidly to con-sumer demands. Flexible equipment lets manufacturers rapidly modify production to suit various levels of product protec-tion and product characteristics, such as from pile to slug packs, with little down-time. For instance, packages can be pro-duced airtight, gas proof, or including a corrugated cardboard around the bis-cuits to prevent mechanical shocks. In addition, there is a range of sealing tech-nologies to accommodate various film qualities. To help improve production and enhance brands, biscuit manufactur-ers and brand managers should take expertise and consultation into consid-eration when purchasing equipment to make sure that the most efficient and appropriate system is purchased.

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need to adopt certain hygienic practices. New automated lines have been designed with hygiene in mind. For example, steel frames are used and streamlined designs prevent trapping product crumbs in holes and crevices. Automation is also inherently more hygienic than semi-automatic operations because fewer workers come into con-tact with food, thus reducing the poten-tial for contamination.

Greening for the future Food manufacturers are also exploring new “green” options to reduce scrap and CO2 emissions. This includes biode-gradable films and reducing the weight of packaging by using thinner foils and

fewer materials. Not only are these options environmentally friendlier, they help decrease overall costs without sac-rificing quality. As food manufacturers attempt to meet the increasing demand in emerging markets and beyond for biscuits of all types, incorporating automated packag-ing technologies will be crucial for suc-cess. Above all, manufacturers need packaging suppliers able to act as con-sultants to help manufacturers find the best solution for their requirements.

For more information please contact:

Daniel Bossel

Phone: +41 58 674 7311

E-mail: [email protected]

One example of shifting consumer demands is the trend towards single-serve packaging. For many consumers, single-serve options convey product freshness since it is meant to be eaten all at once. Additionally, the pack price is more affordable than for bigger packs. Single-serve packaging also adds conve-nience for busy consumers, such as urban professionals or individuals seek-ing portion control or a snack that can be eaten on-the-go.

Focus on hygiene Globally, concerns about food safety are rising, creating new regulations and tightening the ones already in existence. This means that food manufacturers

Based in Beringen, Switzerland, Bosch Packaging Systems AG, a company of Bosch Packaging Technology, brings more than 60 years of experience with biscuits packaging – expertise that manufacturers can leverage to help boost brands and seize market share. Bosch’s new high-speed biscuit line is designed for maximum flexibility and the fastest changeovers currently available on the market. From distribution through end-of-line technologies, the biscuit line is a seamless system that optimizes OEE, taking manufacturers to the peak of productivity.

6 | packazine News Facts & Trends

With a clear commitment to freshness, quality and sustainability, dairy company Kärntnermilch is strongly grounded in the region Kärnten. The company is com-mitted to bringing fresh dairy products to chillers while being mindful of its responsibilities towards nature and the environment. With headquarters in Spittal/Drau, Austria, the company is also a farming cooperative association with 180 employees, making it the

livelihood for more than 1600 agricul-tural companies in the region.Every year, Kärntnermilch manufactures more than 100 million liters of milk into high-quality dairy products and in doing so, uses strict quality inspections and state-of-the-art technology to ensure product excellence.The product range comprises fresh and longer fresh whole and semi-skimmed milk amongst other cup products such

as sour cream, mascarpone and lactose-free products. In addition, Ramino Käse-traum, Drautaler and various naturally matured cheese such as Mölltaler Alm-käse are produced. Organic products under the trademark Bio+ account for a third of Kärntnermilch’s production. The non-genetically modified organic dairy products are highly popular with consumers. The company, which was originally founded in 1928 as

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Flexibility in the dairy industryKärntnermilch increases productivity with innovative solutions from Bosch subsidiary Ampack

“Oberkärntner Dairy”, is now a market leader and the largest dairy in Kärnten. In order to fulfill high quality demands on their dairy products, the company planned the installation of a new ma-chine for the filling and packaging of cup products, including yogurt, sour cream, fruit yogurt and crème fraiche, and was looking for a suitable partner.

High demands in the food sectorKärntnermilch had high requirements of the new filling and sealing machine: It should offer maximum flexibility and output while also being reliable. Kärnt-ner milch eventually decided upon the packaging machinery specialist Ampack. The company has been part of Bosch Packaging Technology since 2012 and develops, manufactures, and sells filling and packaging machines as well as dos-ing systems and peripheral machines for liquid and viscous food with a world-wide distribution network. Since 2005, the company has also been undertaking its own research in the area of aseptics and operates a microbiology test labora-tory. As packaging machinery specialist, Ampack was best able to respond to Kärntnermilch’s requirements of quality and reliability.The Ampack inline machine now used by Kärntnermilch is a filling machine de-signed with eight tracks, which can fill various products, including different yo-gurts, viscous desserts and sour cream in premade cups. Stations include cup infeed, double cup control detection, sterilizer, piston valve for pre-dosing, ro-tary valve for main dosing, lid placing

station, sealing station, foil lid control, snap-on lid station, and packer. With its different stations, the machine, which has been used for production since 2013, is optimally suited for the compa-ny’s broad product range.

Flexible design, highest qualityMichael Dorner, deputy head of produc-tion at Kärntnermilch, “Our main goal is to bring our customers the commodity of milk and other milk-based products at the highest possible quality. The dairy products that we produce have to be processed as quickly as possible to meet strict hygiene standards and must arrive fresh at the chillers. Therefore a filling machine with low downtime and minimal machine stoppages is of vital importance to Kärntnermilch. Ampack not only convinced beforehand being a strong partner with developing a cus-tomized filling machine, but also pro-vided highly reliable technology.”From its partner, Kärntnermilch expects high productivity and maximum flexibil-ity in packaging, for example the ability to also equip cups with a snap-on lid during the packaging process. This diversity of options in the design of the inline machine’s stations means that Ampack ensures optimum customization to client requirements.As Kärntnermilch packages different products with the machine, it had to be equipped for this product variety. The integrated sterilizer ensures the steriliza-tion rate and guarantees that each prod-uct meets the necessary hygiene stan-dards. Moreover it is fundamental that

reliable sealing is guaranteed. At the foil lid control, the sealing of the cups is inspected so that only securely sealed cups reach end-of-line packaging.

Investment in the future“The machine from another supplier which Kärntnermilch used for a long time previously no longer met the stan-dards which had developed over the past ten years in dairy production. With the new filling machine from Ampack, we have invested in the future. Already two weeks after commissioning, production could be moved to the new filling machine”, says Dorner. Since then, the high-performance machine which was developed for the production of dairy products has been in constant op-eration, 24 hours a day from Sunday evening until Friday evening – in three-shift operation with an output of 21 000 cups per hour.

Results speak for themselvesWith the new machine, Kärntnermilch has increased its production by 40 per-cent. Because the Ampack machine enables a higher output, additional time opportunities open up allowing Ampack to realize orders at short notice. Time optimization is achieved by way of an improved production and sanitation pro-cesses. Moreover, the format of packag-ing can be varied – cups with different volumes and made from different mate-rials can be used, as well as product changes can be implemented quickly. The filling accuracy of the new machine amounts to a reduction in unnecessary

8 | packazine Customers & Markets Food and Confectionery

product waste. Also machine operation became easier for operators due to larger magazines.For Kärtnermilch, the project was a suc-cess across the whole line: Ampack has proven itself with innovative technology and outstanding service. Dorner empha-sizes, “We are extremely pleased with Korbinian Tomschi as project manager and main contact person, as well as with his project team. They have worked very quickly and provided excellent support throughout the entire project.”


Markus Schlumberger

Phone: +49 8231 6005 918


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Wildlife Sciences, located in Min-netonka, Minnesota, manufactures a wide range of suet-based bird food un-der its Suet Plus® brand. An energy-rich food that insect-eating birds love, suet is the hard fat from a beef carcass. When used as bird food, it is commonly combined with bird seed, corn meal and other grains and nuts and formed into

cakes, balls or plugs. Handling and load-ing these fat-based products into bird feeders can be a sticky situation. To make its products cleaner and easier to handle, Bill Gleason, president and David Pichotta, co-founder of Wildlife Sciences, developed new processing and packaging for their products.

Messy mixTraditionally, suet-based bird food has been packaged in trays that were then lidded. However, this method trans-ferred the grimy handling to the cus-tomer who had to extract the cake from the tray when loading bird feeders. To eliminate the need for consumers to have direct contact with the product,

Packaging that’s not “for the birds”Wildlife Sciences’ innovative bird food packaging sparks strong growth


demand, Gleason purchased additional Bosch wrappers, the Doboy Mustang and Doboy Stratus, for the company’s production line.

Putting a feather in its sustainability cap The new packaging also offers signi-ficant environmental benefits. It uses 80 percent less packaging by weight compared to the former tray solution and is composed of 100 percent recy-clable materials. Since the packaging is generated from flat rollstock film, it requires significantly less space for transportation, reducing the overall car-bon footprint. Positioned for future growthIn 2012, Wildlife Sciences’ business had outgrown its existing plant and the com-pany moved to its current location in Minnetonka, MN, which offers triple the production space. In 2013 the company added another packaging line. “I have always been impressed with the perfor-

mance of Bosch’s technology and its customer support, so I purchased the Pack 101, Bosch’s new entry level flow wrapper. It’s robust, flexible and easy to clean,” says Gleason. The company now also produces and packages the bird food cakes for private label. “The one-piece flow wrap design allows us to print vivid graphics around the entire package,” Gleason notes. “Not only does this allow retailers to display the product in several attractive ways, but the attractive packaging also creates shelf differentiation.” Wildlife Sciences’ business continues to grow and the company is considering adding another production line in 2014.


Paul Garms

Phone: +1 715 246 6511


Wildlife Sciences selected a packaging format similar to a chocolate bar flow wrap. This packaging has a serrated edge that enables customers to simply tear open one end of the package and slide the cake out of the package and into the bird feeder. While simple in concept, handling the sticky, greasy products without a tray required cus-tomized processing technology. Wildlife Sciences also had the challenge of finding packaging technology, specifi-cally a horizontal flow wrapper that was robust enough to form a high-quality wrap while the machine is coated in fat from the suet cakes that contain gear-jamming nuts and seeds. After consult-ing with equipment dealers for recom-mendations, Wildlife Sciences pur-chased a Doboy H-400 horizontal flow wrapper. It reliably packages the prod-ucts in a two-shift operation and down-time for cleaning is only needed once per week. Wildlife Sciences witnessed sales of Suet Plus® surge. To meet increasing

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Norwegian premium coffee roaster ramps up for successAddition of vertical packaging line from Bosch boosts productivity

by 40 percent


Solberg & Hansen opted for an internal valve for its high-quality stand-up bags, which enhanced the package’s visual presentation even further.

Founded in 18791, Solberg & Hansen, a premium coffee and tea importer located in Oslo, makes sure every coffee bean is roasted and packaged to perfection. The company takes coffee bean selection seriously and purchases beans only from winners of the prestigious Cup of Excel-lence competition farms in Rwanda, Kenya, Guatemala, Costa Rica, El Salva-dor, Nicaragua, Colombia, and Brazil.2 The company then roasts the beans and

sells them wholesale and to private label companies, as well as retails coffee un-der its own brand. In 2012 the company won a contract to produce beans for a private label brand in Sweden that would be sold at 150 Swedish coffee bars. To meet increased demand, Solberg & Hansen installed integrated packaging line from Bosch Packaging Technology and was able to escalate productivity by 40 percent.

Moving from small- to medium-sized operations Winning the coffee bar contract was a key milestone in the company’s strategy for the private label sector, and also made clear that its packaging operations, which included two machines for pre-made bags, would not be adequate to meet new production demands. To boost output to the level required, Solberg & Hansen knew it needed to move to a ver-

valves to the inside of packages. “A one-way valve is rather important for preserv-ing coffee freshness,” says Simo Kristidhi, roast master for Solberg & Hansen. “Valves relieve the pressure that builds up inside the pack as coffee releases carbon dioxide, while also preventing oxygen from entering and affecting the aroma.” He adds that the integrated valve applicator from Bosch also creates a sealing seam that is barely visible, help-ing to optimize the bag’s appearance. Choosing an internal valve, rather than an external one, the package’s visual pre-sentation was enhanced even further.

Product savings thanks to highly precise filling technology“At Solberg & Hansen, we strongly believe that the packaging should be just as high quality as the product inside,” emphasiz-es Kristidhi. “With Bosch, we have been able to make that happen.” Kristidhi notes that his team took a holis-tic approach to the packaging process by purchasing a Bosch netweigher (FIW 4011K) and a checkweigher (KWI 5000).

tical form, fill and seal (VFFS) packaging platform. The company considered sever-al manufacturers of vertical packaging solutions, ultimately choosing Bosch.

Advantages of fully-integrated coffee packaging lineAfter collaborating with Solberg & Hansen to identify its specific needs, Bosch rec-ommended a line that has the flexibility to produce four-corner sealed bags as well as standard stand-up bags and in-cludes the Bosch vertical bagger (PME 4001 BG). The bagger runs at speeds of 50 bags per minute for 250 gram, 340 gram, and 500 gram bags with four-corner seals. It also produces 1 kilogram block-bottom bags at a rate of 45 bags per minute.The vertical bagger offers an intermittent motion operation that enables long seal-ing times for air-tight bags which enhanc-es product protection by preserving the aroma of the delicate beans. To further enhance operational efficiency, Solberg & Hansen also purchased an integrated Bosch applicator (CVA 2000 VIS) to seal

The netweigher provides one-step weigh-ing using strain-gauge cell technology, which produces an exact weight. The KWI checkweigher performs an accurate weight and quality control check of prod-ucts at the end of the packaging line, conforming to the requirements of the European Measuring Instruments Direc-tive (2004/22/EC). Kristidhi says the new packaging line has provided the operational improvements that Solberg & Hansen sought, while strengthening the coffee’s brands premi-um quality image.


Marcus Velezmoro

Phone: +49 711 811 57850


1 Source: Dear coffee, I love you, May 2004, http://www.dearcoffeeiloveyou.com/solberg-hansen/2 Source: Alliance for Coffee Excellence, http://www.allianceforcoffeeexcellence.org/en/cup-of-excellence/

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Winning a coffee bar contract was a key milestone for Solberg & Hansen.

To meet increased demand, the company purchased a fully-integrated

coffee packaging line from Bosch.

While the samovar1 is no longer a must in every Russian home, the tradition of tea-drinking is very much alive in the country. Because Russian people usu-ally drink tea after every meal, the con-sumption of sweets is deeply rooted in Russian culture. To capitalize on this tradition, Essen Production AG, a Rus-sian food manufacturer famous for its Makheev mayonnaise brand, decided to enter the confectionery market.

New plant, new product, new line Today, Essen Production offers more than 100 products under the Makheev brand, including ketchup, sauces, jams, spices, snacks and mayonnaise. In 2011, after ten successful years in the market,

the company acquired an old meat pro-cessing factory in Elabuga, the Republic of Tatarstan, which is a region of the Russian Federation, and converted it into a cutting-edge confectionery pro-duction facility. The company’s first confectionery products include a range of wafer sweets: “Arami”, “Moya lubi-maya Jozy” (translated as “my beloved Jozy”) and “Vafelnaya Konfetka” (trans-lated as “wafer sweets”). “Arami” is a glazed wafer treat with whole hazelnuts, “Moya lubimaya Jozy” is a semi-glazed wafer with whole hazelnuts, whereas “Vafelnaya Konfetka” is a bar consisting of three wafers.In December 2012, Essen Production’s first confectionery product under work-

ing title “Konfetka” (translated as “sweets”) began its maiden voyage to the tea tables of Russian sweets lovers. “The new treat has instantly found its fans,” said Oleg Sukhorukov, deputy general director confectionery, Essen Production. When looking for a suitable packaging line, Essen Production sought out a solution that would offer the flexibility to package a variety of wafer products and address ever changing consumer preferences. After evaluating several packaging suppliers, Essen Production chose the solution from Bosch Packag-ing Technology consisting of the Lane

Tea Time, Sweets TimeBosch and Essen Production join forces to offer a new treat

in Russian confectionery market

1 Traditional Russian tea brewing device, tea urn


Distribution System (LDS), five inline feeders (Pack Feeder 4) and five flow wrappers Pack 401. The Pack 401 ma-chines are executed in a 4+1 configura-tion, which allows for undisrupted oper-ations since one of the five lines is al-ways on standby mode and can be used as a backup when another wrapper needs to be offline for maintenance, cleaning or any other issue.

Seamless lineTo ensure that small wafers are pack-aged without bottlenecks and down-time, Bosch introduced its LDS (Lane Distribution System). The oscillating diagonal positioned side guides stream-line the products into four equal rows,

one wafer behind another, in perfect or-der to avoid jams and other related machine stoppages. The wafer rows are then diverted to the modular product infeed system and transferred to the Pack 401 horizontal flow wrapper. Bosch’s LDS was specifically developed for small products and accommodates random product arrival at high produc-tion rates. Able to process up to 2600 wafers per minute, the line achieves the highest possible efficiency by ensuring that products are automatically trans-ported from one line part to another in the event of a breakdown. In addition, different modules, such as buffering and product inspection, across the entire packaging line ensure

that the quality of the delicate wafers is maintained throughout the packaging process. Waste and damage levels are therefore kept to the absolute minimum.

Wafers in all varietiesBecause Russian consumers enjoy vari-ety and choice when it comes to sweets, Essen Production developed several versions of its confectionery treats. To ensure all of these product variations could be handled efficiently, Bosch designed a streamlined packag-ing line, which seamlessly integrates the LDS, infeed system and Pack 401 hori-zontal flow wrapper. The line’s compact footprint allows Essen Production to make optimal use of its available pro-

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lows changeovers to a new film reel without stopping the machine. This fea-ture not only reduces the total cost of ownership (TCO) of the system for Es-sen Production, but also allows the company to package its new treats more efficiently and be prepared for growing market demand. “Bosch’s solution provides us with the option of quick upscale as wafer treats gain popularity,” says Sukhorukov. “This positions us for our anticipated growth over the next few years.”

The future is sweetEssen Production is looking to expand its confectionery facility and product of-ferings. Partnering with Bosch Packag-ing Technology has allowed the Russian

manufacturer to successfully enter the confectionery sector and respond to the ever-growing craving for sweets in Russia. “With Bosch we have found a reliable partner who provides support during every stage of the new product develop-ment process; from development, to consultation, to integration and factory acceptance testing,” says Sukhorukov. “We look forward to continuing our work together as we further grow in the Russian confectionery market.”


Leon Arkesteijn

Phone: +31 10 4885 727


duction space. In addition, the horizon-tal flow wrapper features easy to oper-ate electronic controls and mechanical reproducible adjustments for quick changeovers and reduced downtime.

High-speed for growing wafer cravingTo prepare itself for rapid increases in production volumes, Essen Production also required its packaging solution to have the ability to adapt from semi- to full automation, and from medium- to high-speed wrapping. The Pack Feeder 4 is capable of belt speeds up to 120 me-ters per minute, whereas the Pack 401 flow wrapper packages around 700 wa-fers per minute. To further maximize up-time, the Pack 401 features an auto-matic film splicer with a sensor that al-


The tradition of tea-drinking is very much alive in Russia. Russian people usually enjoy sweets with tea, such as wafers from Essen Production AG.

summer time and Oseibo at the end of the year. Not surprisingly, the Japanese place special emphasis on packaging their gifts. No one knows this better than Mr. Yoshito Harada, the fourth generation CEO of Harada Ltd., a premium confec-

tionery manufacturer based in Takasaki, Japan. High-quality sweets make for popular gifts, and Mr. Harada aims to create confections that are superior in quality. This, he insists, must be re-flected not only in how they taste but also in their branding and packaging.

Gentle and efficient handling of rusks increases production output

Innovative robotics sweeten production for premium Japanese confectionery

The Japanese thank each other for sup-port and express their gratitude through the exchange of gifts. In Japan, gift- giving is perceived as a form of art, with tradition calling for the Japanese to bestow gifts on one another at least two times during the year – Ochugen in

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Confectionery treats from the “castle of happiness”Harada Ltd. started its manufacturing operations in 1901 as a Japanese con-fectionery (Wagashi) company and later begun bread making in 1946 for a local customer base. Today, with a robust mail and e-commerce business and 15 premium boutiques across Japan, the company’s business has grown ten-fold in the last decade. Most of its retail out-lets are housed within high-end depart-ment stores; however, the company runs a few stand-alone boutiques, including one next to its headquarters called Cha-teau du Bonheur. In English, this trans-lates as “castle of happiness,” and as Mr. Harada explains, happiness is a core value of his company. “We believe that customers can feel a small sense of hap-piness from a single piece of confection-ery,” he says. Harada’s top-selling product is the Gâteau Rusk “GOUTER de ROI”, a line of crunchy, butter-rich rusks made from slices of the company’s famous French baguette bread. Each slice is applied with butter oil, sprinkled with sugar and features various coatings depending on the line. GOUTER de ROI Premium is coated with milk chocolate; other rusk series include GOUTER de ROI White Chocolate and GOUTER de ROI Somme-lier (unsweetened rusk for wine). In 2003 the GOUTER de ROI product won the Golden award at the National Confectionery Exposition, and it has been hugely successful in Japan. In or-der to meet rising demand and a boom-ing mail order business, Harada needed

packaging technology that could support high-speed operations and offer signifi-cant flexibility.

Delta robots for high-speed production The company found a solution with the DELTA C2000 parallel mechanism robot from Bosch Packaging Technology. Spi-der-like and lightweight, the delta robot is capable of moving objects on a pack-aging line at high speeds with pinpoint precision. It is ideal for high-mix, low volume applications in which multiple products are processed on the same packaging line. Changeovers can be made quickly and output can be in-creased or decreased easily based on fluctuating demand.Harada installed its first delta robot in 2007 on the GOUTER de ROI White Chocolate line. The robot, which was manufactured and tested in Japan, was deployed on the line to supply rusks to the horizontal packaging equipment that, in turn, packed them into flow wraps. Today, Harada uses 15 delta robots for both primary and secondary packaging operations. Loaves of bread are baked in tunnel ovens measuring 30 meters long for half an hour. The bread is then cut into slices and baked again with gener-ous portions of butter and sugar. The delta robots are positioned to move rusks into horizontal packaging ma-chines, while other Bosch robots trans-port rusks packaged in flow wraps and sort them into retail-ready trays. The high-speed robotics help Harada pro-duce 1.3 million rusks every day.

Gentle handling is the keyAccording to Mr. Harada, a key advan-tage of the DELTA C2000 robot is its abil-ity to gently handle the brittle rusks, pre-venting damage and lost product. In ad-dition, unlike the legacy robotics equip-ment, the delta robots from Bosch can combine two rusks together in one stack by a chucking method. Using advanced image detection technology, the delta ro-bot assesses the exact size of each rusk, determines its gravity point, gradient, shape and size, and then matches it with a similarly-sized slice for stacking.This unique double stacking method speeds per-cycle operations. Four robots across two lines are able to move 252 rusks per minute. Double stacking also results in fewer crumbs and sugar gran-ules falling off rusk slices and onto the conveyor, making cleaning easier and re-ducing the downtime for maintenance.The DELTA C2000 robot needs low main-tenance in several other ways as well. Other robotics technologies, Mr. Harada says, require regular repairs and equip-ment overhauls once every two to three years. By contrast, the Bosch delta robot requires no overhaul and is nearly main-tenance-free because there is less wear on parts. “As a result, we were able to reduce time for upkeep and adjustment by 99 percent, while maintenance costs were cut by 90 percent,” he explains. Mr. Harada reports that the delta robot is helping his company to stay ahead of the quality control curve. “By using state-of-the-art manufacturing technology, our products have greater consistency and homogeneity. We have improved our


efficiency and our ability to stabilize pro-duction, while assuring superior quality for our customers,” he says.

Robots that speak Japanese Tailored for Japan, the DELTA C2000 ro-bot’s HMI allows operators to communi-cate and adjust the machine in Japa-

nese. If more support is needed, the lo-cal team of Bosch experts is available for fast troubleshooting. This local ser-vice support – both in terms of language capabilities and geographical proximity – has been a benefit to Harada. “An im-portant factor in our decision was the fact that Delta robots could be tested in

Japan and that Bosch has a team of technical experts here as well,” states Mr. Harada.


Armin Radzwill

Phone: +81 3 5466 2550


packazine | 19

Treating root causes instead of symptoms

Mondelēz Ireland, the manufacturer of Cadbury chocolate,

wanted to increase the operation effectiveness of its automatic

packaging line for Cadbury Flake bars. Together with

Bosch Packaging Services, Mondelēz Ireland implemented a

very successful OEE (Overall Equipment Effectiveness) concept,

which resulted in an improved performance.


Mondelēz Ireland is a market-leading producer of chocolate, biscuits, gum, candy, coffee and powdered beverages. The vast portfolio includes popular brands such as Cadbury, Côte d’Or, Milka, Toblerone, Jacobs coffee and Halls. The factory in Coolock, Ireland, produces several key brands including the popular Cadbury Flake bar. With a tight production schedule, the site de-pends on smooth processes and a con-tinuous flow of production. In 2010 the packaging line for its Cadbury Flake bars was not achieving the required output. “At that time, performance was not con-sistent across all machines,” explains Da-vid Lindsay, production engineering man-ager at the Coolock site. “We worked on the Bosch packaging line ourselves but productivity was still not meeting our ex-pectations. That’s when we decided to enter into a partnership with the Bosch team to address the issues.”

Continuous approach for sustainable improvementMondelēz Ireland invited Bosch senior management and the colleagues from the customer service hub in Derby, UK, to define a continuous improvement

plan. Bosch decided to take their OEE specialist along. “Our expert explained how the Bosch OEE approach could be used to help work through the issues of the Cadbury Flake bar packaging line,” says Martin Orgill, head of service sales at Bosch Packaging Services. David Lindsay from Mondelēz Ireland adds, “Since the project required a structured method over a certain period of time, a trustful and open partnership with Bosch was very important for us. We knew of the OEE idea in principle, but we were keen to learn more.”The calculation of OEE considers three of the most common reasons for produc-tivity losses: availability, performance and quality. These factors are expressed in percentages as comparative values and form the basis of Bosch’s OEE im-provement project. They are collected with a measuring system over a period of approximately four weeks and docu-mented in a chart, showing which indica-tor has a negative impact on OEE. Based on the causes of those three factors, the Bosch OEE experts can implement a continuous approach for sustainable equipment improvements and increased effectiveness. This concept matched per-

fectly with the packaging equipment issues Mondelēz Ireland was experienc-ing in Coolock.

Specialized project teamMondelēz Ireland and Bosch selected the flow wrappers for primary packaging and top loaders for a first assessment, as they were causing most production stops and delays. The customer service team from the UK hub conducted a close audit of the situation during actual pro-duction. On 23 consecutive days, they monitored the selected machines, col-lected production data from the three key areas and statistically evaluated these figures. The results revealed that the availability factor was responsible for most OEE losses. The evaluated produc-tion data provided a first indication of possible causes and showed the fre-quency of machine downtime notifica-tions, which are responsible for availabil-ity loss. Mondelēz Ireland and Bosch set up a specialized project team, consisting of machinery and product experts from Mondelēz Ireland as well as engineering specialists and an OEE expert from Bosch, to systematically work through the OEE improvement steps.

packazine | 21

“During our first OEE workshop in August 2011, we presented an overview of the findings of our machine analysis,” Martin Orgill says. David Lindsay adds, “It was a very open and honest ex-change. We shared our goals and de-fined clear and measurable objectives.” This included a proposal of how to match the process knowledge of Mondelēz Ireland’s engineers best with the know-how of the Bosch machine specialists. “Detecting the symptoms is one thing, but getting to the root causes is the actual aim”, Martin Orgill and David Lindsay agree. In the second OEE workshop, the Bosch team evaluated the impact of the defined causes in a Failure Mode and Effects Analysis (FMEA). Answers to questions like ‘How severe is the effect?’ or ‘How often does this issue occur?’ helped to prioritize potential failure effects, for instance ‘no product at infeed’, ‘balance the speed of the line’, and ‘auto restart proce-dures’. The team then determined mea-sures of improvement, such as creating

new settings for the different multipack formats.

Making the most of plant and peopleAfter implementing the defined mea-sures, the project team carried out a more intense equipment performance analysis, based on 90 days of measure-ments on the flow wrappers and top loaders, and presented the findings in the third and last OEE workshop in June 2012. “This meeting was very in depth and specific to key machine areas based on the fault types and frequencies,” Martin Orgill explains. “We reviewed the results of the machine performance with utmost care to ensure that the correct conclusions were extracted.” The OEE improvement project from Bosch not only made it possible for Mondelēz Ireland to analyze and prioritize the machinery issues. It also led to an im-provement of equipment effectiveness in terms of reduced machine downtime and both increased and consistent perfor-mance standards.

According to the latest statistics, David Lindsay confirms that “performance has improved significantly”. More impor-tantly, Mondelēz Ireland has been able to sustain this improvement. “This success is based on clear data that we collected with Bosch and the shared know-how regarding our machines and production cycles. The stages of the OEE approach were clearly set and well communi-cated,” David Lindsay says. “Our employ-ees were also great in supporting us. After familiarizing with the OEE concept, they saw the need for change and we achieved those positive results together. Treating the root causes instead of only the symptoms, together with a reliable and professional partner, supported us in making the most of our plant and people in Coolock.”


Martin Orgill

Phone: +44 1332 626267



Headlineauch mehrzeilig

Lead

Events Food 2014/2015

Events Pharma2014

Date Event Location Branche

05.08. – 05.14.2014 Interpack Dusseldorf General

06.03. – 06.06.2014 Fispal Tecnologia São Paulo Food

06.10. – 06.13.2014 United Fresh Tec Chicago Food

06.10. – 06.13.2014 Fooma Japan Tokyo Food

06.11. – 06.14.2014 Pack Plus New Delhi Food

06.17. – 06.20.2014 Expo Pack Mexico Mexico City Food

06.19. – 06.21.2014 Afro Packaging Cairo Food

07.16. – 07.18.2014 Propak China Shanghai Food

09.24. – 09.25.2014 Empack Brussel Food

09.25. – 09.27.2014 International Pack Tech India Mumbai Food

10.06. – 10.10.2014 Agroprodmash Moscow Food

10.07. – 10.10.2014 Tokyo Pack Tokyo General

10.21. – 10.23.2014 Propak Cape Cape Town General

11.02. – 11.05.2014 Pack Expo International Chicago Food

11.09. – 11.11.2014 Gulfood Manufacturing Dubai Food

11.14. – 11.16.2014 International Food Tech India Mumbai Food

11.17. – 11.20.2014 Salon International d'Emballage Paris General

01.27. – 01.30.2015 Upakovka Moscow Food

02.01. – 02.04.2015 ProSweets Cologne Food

03.24. – 03.27.2015 Anuga Foodtec Cologne Food

DateEventLocationBranche

05.08. – 05.14.2014Interpack DusseldorfGeneral

05.12. – 05.14.2014FCE Pharma São PauloPharma

05.20. – 05.22.2014P-Mec South East AsiaJakartaPharma

06.03. – 06.05.2014Vision PharmaStuttgartPharma

06.26. – 06.28.2014P-Mec ChinaShanghaiPharma

07.02. – 07.04.2014Interphex JapanTokyoPharma

09.01. – 09.03.2014Pharmex AsiaBangkokPharma

09.29. – 10.03.2014ExpoquimiaBarcelonaPharma

09.30. – 10.02.2014Technopharm/PowtechNurembergPharma

10.06. – 10.10.2014SupplySide WestLas VegasPharma

10.07. – 10.09.2014P-Mec WorldwideParisPharma

10.07. – 10.10.2014Tokyo PackTokyoGeneral

10.12. – 10.15.2014ISPE Annual MeetingLas VegasPharma

10.14.– 10.16.2014A3P Congress BiarritzPharma

10.21. – 10.22.2014PDA Visual InspectionBerlinPharma

10.21. – 10.23.2014Propak CapeCape TownGeneral

10.21. – 10.24.2014Allpack IndonesiaJakartaPharma

10.28. – 10.31.2014China PharmShenzhenPharma

11.02. – 11.05.2014Pharma ExpoChicagoPharma

11.02. – 11.06.2014AAPS Annual MeetingSan DiegoPharma

11.17. – 11.20.2014Salon International d'EmballageParisGeneral

11.25. – 11.28.2014PharmTechMoscowPharma

12.02. – 12.04.2014P-Mec IndiaMumbaiPharma 11/22-11/25/10

packazine | 2323 | packazine Events 2014/2015

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