Bosch packaging solution for biscuits at Gulfood Manufacturing

AT Gulfood Manufacturing 2015, Bosch Packaging Technology puts the spotlight on it latest machine, the Pack 301 LS (Length Slug) system for wrapping biscuits and crackers on edge. The machine is an addition to the company’s Pack Series of horizontal flow wrappers, which range from entry-level models to fully automated technologies.

At the show the packaging solution will be manually loaded. The system is comprised of the Smart Slug Feeder as well as the Pack 301 LS horizontal flow wrapper. For automated loading, Bosch’s Smart Measuring Loader can be easily integrated in the system. Among product features are gentle handling and fast and simple changeovers.

The Pack 301 LS is designed for the efficient and flexible packaging of biscuits and crackers on edge. The mid-range automation packaging system is comprised of a Smart Measuring Loader, a Smart Slug Feeder and a Pack 301 LS horizontal flow wrapper. Alternatively, the system can be loaded manually. (Photo: Bosch)

“Working closely with our customers in the Middle East, we are seeing increasing demand for full-line automation to address growing market needs and evolving consumer demands,” says Feyssal Omar, regional sales director, Middle East and North Africa, Bosch Packaging Technology. “To enable Middle Eastern biscuit producers to get ahead of the competition and enhance flexibility, we have developed the Pack 301 LS. Its highly versatile layout configuration, fast changeovers and easy maintenance help bakery manufacturers increase adaptability and enhance their competitive advantage.”

Reliable product handling

Even at high speeds, the Pack 301 LS system including the Smart Measuring Loader for slug portioning can handle delicate and brittle biscuit-type products. Transfer points from the loader to the cross chain, from the cross chain to the infeed chain and further into the film tube generally pose the greatest risk for product damage and breakage. Due to the full-servo execution, the Smart Measuring Loader allows for smooth placement of the portioned biscuits into the cross chain. The Smart Transfer Unit features pre-acceleration for optimal synchronization with the infeed chain. It therefore eliminates impact on the product when bringing it from the cross chain into the machine infeed, ensuring gentle, reliable handling. To keep the biscuits in an upright position while being transported into the film tube the biscuit portion is supported by a counter holding pin. The position where the counter holding pin comes up can be easily modified by the operator via an adjusting knob. Between the folding box and the cross-sealing station the slug is guided carefully by side belts or chains towards the cross-sealing station. Depending on the product characteristics, operators can easily exchange side belts with side chains and vice versa for enhanced flexibility and optimal support. All of these innovative features ensure that products are kept under control during the complete packaging process. Additionally, the narrow design of the cutting head improves sealing performance and creates tight seals.

Full-servo product transfer ensures gentle product handling for delicate and brittle biscuits. The Smart Transfer Unit features pre-acceleration for optimal synchronization with the infeed chain. To keep the biscuits in an upright position while being transported into the film tube the biscuit portion is supported by a counter holding pin.

Total productive maintenance

Designed with the operators and Total Productive Maintenance in mind, the solution has been laid out to be accessed from all sides for smooth operation, fast and easy cleaning, and low maintenance effort. The cross chain features a spring loaded chain tensioner with visual feedback, allowing the operator to easily check whether there is optimal chain tension or it should be adjusted. Machine parts in contact with the product are made of stainless steel, meeting today’s hygienic standards. The open design allows crumbs and rejected products to fall through or be removed easily. All of these features add to operator friendliness and boost machine uptime and availability.

A holistic approach for maximized OEE

All aspects of the Pack 301 LS are designed to minimize downtime and enable stable output at high production speeds. To increase Overall Equipment Effectiveness (OEE), the complete biscuit feeding and packaging solution is operated by a single HMI, which enhances fast changeovers for different formats and sizes. In addition, whenever a product is missing, the “no product – no cycle” option stops both the infeed and the machine when a product is missing to avoid empty packages. Thanks to optimized interfaces, the integrated system can be provided with all required upstream equipment including vibratory channels, offering a complete solution from a single supplier.

Flexibility for product shapes and lay-out configurations

Developed to address current and future market requirements, the Pack 301 LS system is capable of packaging rectangular, square and round products, as well as sandwich biscuits. Depending on the manufacturer’s requirements, the solution can be equipped with up to ten vibratory channels. The modular design allows for scalable solutions and layout flexibility, enabling manufacturers to easily expand their production capacity or increase the level of automation from entry level, hand fed machines to fully automated solutions.

The Pack 301 LS system will be displayed at Gulfood Manufacturing in Dubai World Trade Centre in Dubai, UAE, from October 27 to 29 in TC hall, booth S-E24.