packazine - bosch packaging€¦ · food & confectionery · issue 2013 kenafric | first chewing...

Food & Confectionery · Issue 2013

Kenafric | First chewing gum line of its kind in AfricaHeinz | New format for baby food packaging Mondelēz International | Modernisation of cheese production

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www.boschpackaging.com [email protected]

2 | packazine Table of contents | Editorial

News

Facts & Trends04 Product quality | Protection all around

Customers & Markets

Food & Confectionery07 Kenafric | First chewing gum line of its kind in Africa

10 Heinz | Good for babies, good for Mother Earth

13 Nature’s Path | The path to success

16 Mondelēz International | Time is money, and cheese

18 Endangered Species | Charitable chocolate company finds sweet success

21 Otmuchow | Otmuchow triples output of jelly production with turnkey solution

Events

24 Events 2013

CoverFor the production and packaging of its

successful chewing gum brand “Fresh” Kenafric relies on a solution from Bosch.

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Customer magazine of the Packaging Technology Division,Robert Bosch GmbH

Editor in ChiefCentral MarketingChristin Pönisch Phone +49 711 811 [email protected]

DesignCentral Marketing, Karin Schmückle

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

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,

No matter which industry we work in – packaging is part of our daily life. It protects food and pharmaceuticals, from coffee to insulin. In this regard, you as our customers

and we, as a provider of process and packaging solutions, are not only manufacturers but consumers. It is we who make greater and greater demands for improved product quality, safety and shelf life. These requirements are reflected in the introduction of increasingly stringent regulations for product protection, both in the pharmaceutical as well as food and confectionery industries. More and more, packaging is also perceived as a means of extend-ing shelf life to save resources and improve food provision for millions of people. Packaging is Invented for Life. Product protec-tion and quality, therefore, is the focus of this edition of packazine.

Goods, both pharmaceutical and food, should reach the customers with the quality they expect. We are dedicated to helping manufacturers meet this goal with the innovative process and packaging technology we offer. This is why we constantly seek to advance existing technologies and to develop new methods to optimize product quality, from production to the consumer: “Produced and packaged as promised” – as consumers and we ourselves would expect. Our acquisitions in 2012 mirror this philosophy. With Eisai Machinery we extended our competencies in the field of inspection technology for the pharmaceutical industry, helping to make our customers´ products safer by inspecting for filling levels or for contamination from foreign particles. Fully-automatic inspection will be one of the key technology topics in the coming years. Our entry into product inspection via Eisai Machinery is a cornerstone for further technological developments. With the acquisition of Ampack, we extended our equipment portfolio with cup and bottle filling machines for the filling and packaging of highly sensitive food, such as dairy products and baby food. Once again, our technology reflects the same motto: Invented for Life.Many of the products you encounter in your daily life will be represented in the exciting success stories in this edition of packazine. Learn more about how our process and packaging technology helps our customers ensure their products reach consumers safely.

Enjoy the new packazine!Yours,

Friedbert Klefenz

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Friedbert KlefenzPresident,

Bosch Packaging Technology

Editorial

Protection all aroundThe contribution of packaging machine manufacturers to product quality and protection

Product quality has never been that present in the mind of consumers as today. Products of poor quality getting into the market can potentially cause serious damage to a company´s reputa-tion. Furthermore, distributors, caterers and food manufacturers risk claims for compensation in case impairment actu-ally occurs. Consumers are frequently faced with scandals in the food sector, which are leading to global product recalls. As a result, the entire supply chain is increasingly in focus of public perception. Changing transportation routes due to a further proceeding glo-balization also gain more and more in importance. Another issue concerns the

legal requirements for quality assurance and food safety, which have become more complex. Leading policies are for example the “International Featured Standards” for the evaluation of quality and the safety of food, which implement the requirements of the Global Food Safety Initiative (GFSI) and the goals of the Food and Drug Administration (FDA). Consequently, for food manufacturers it is not just about the voluntary imple-mentation of standards, but about mar-keting their products with a high quality standard and complying to changing legal regulation at the same time. This ensures manufacturer´s brand protec-

tion, assures consumer satisfaction and prevents product recalls. In this context, shelf life of goods plays an important role. Packaging machine manufacturers´ solutions can contribute in various ways to extend shelf life of products. On the one hand, appropriate methods applied already during the packaging process ensure product quality and protection. On the other hand, a proper packaging solution contributes to high quality and safety after the packaging process.

Properly packed: hygiene is paying offIt is generally known that microorgan-isms affect food hygiene. And microbial risks increase, for example due to the

4 | packazine News Facts & Trends

upcoming demand for food produced gently and under low heat influence, like ready meals. At that point micro-organisms can breed, because they are not killed by cooking. Furthermore, con-sumers favor food which is low in sugar, salt and fat, and contains no preserva-tives. This poses additional risks of food spoilage.Because of these reasons hygiene is very important in all areas of food pro-duction, starting with the material of process and packaging machinery all the way to the cleanability of equip-ment. The European Hygienic Engineer-ing and Design Group (EHEDG), an expert group of machinery and compo-nent manufacturers, regularly publishes guidelines on how hygienic design can be implemented. For harmonization with the U.S. equivalent of 3-A Sanitary Standards, both organizations regularly have consultations. To meet the increas-ing demands, these organizations for

instance call for filling devices for dry food to be easy to clean, too. The cleanability of such systems should be validated if possible.

Tightly sealed seams for product protectionTo ensure product protection during the packaging process, manufacturers offer versatile solutions such as different sealing technologies like hot, cold or ultrasonic sealing. It is particularly worth mentioning that the pre-packaged products are handled considering their individual characteristics. A disadvan-tage of today very popular hot sealing technology is the heat influence on the product. Ultrasonic sealing here clearly offers a benefit as it is a “cold” technol-ogy. Using ultrasonic sealing further is a possibility to reduce product loss while preserving product protection. It avoids the risk of diminished seal quality and leakage due to contamination of the

sealing area. The high frequency ultra-sonic vibrations remove product resi-dues from the sealing area, thus enabling a reliable joining of surfaces. The resulting seals are secure, ensuring the product is tightly packaged. Thus, ultrasonic sealing is a method to main-tain product quality during and after the packaging process and simultaneously contributes to protection of the pack-aged product. Adequate shelf life is taken care of.

Guaranteed product freshness – during processing and packaging One of the most effective methods to preserve perishable foods is the incor-poration of modified atmosphere pack-aging (MAP) technologies. The air con-tained in the packaging is replaced by a gas mixture, like from nitrogen, oxygen or carbon dioxide, which is adjusted to the product to be packed. This kind of protective packaging reduces the

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against oxygen, water or light. The choice of the appropriate packaging material therefore is crucial. Lightproof packaging material as for example composites with UV barrier or colored glass help with light-sensitive goods. For water-sensitive products, steam barriers contained within the packaging material are recommended, as for example, AI-metallization, polyethylene or polypropylene. Packaging mate-rial like aluminium protects oxygen-sensitive goods from air penetrating the packaging. Every application needs the appropriate material. Often, the harmful oxygen is already contained within the product and its packaging. Different procedures are available to either remove the oxygen or to keep it out of the package. This

includes the vacufin procedure with the generation of a defined vacuum inside the package and neutrafill, a method of adding protective gas as well as neutra-vac, a combination of both procedures. However, beside these methods one thing special should not be forget. So-called Aromafin valves for coffee pack-aging, which are applied to the packag-ing on the one hand prevent the entrance of harmful oxygen. On the other hand, they allow the gas produced by the roasted coffee to escape from the package. This is a perfect method to preserve quality.

ConclusionFood manufacturers have different possibilities to implement product qual-ity and protection at a high level. The appropriate packaging process and packaging solution are key during the whole flow of goods. Packaging machin-ery manufacturers render assistance and also work on new methods in future, to meet coming demands.

Authored by Prof Dr Bernd Wilke, head of engineering and technology support, Bosch Packaging Technology

For more information please contact:

Prof Dr Bernd Wilke

Phone: +49 711 811 57813

E-mail: [email protected]

growth of microorganisms and extends shelf life of the product. Packaging with protective gas maintains product quality without affecting taste, quality, consis-tency or nutritional content.Thanks modern packaging machines which feature devices for hermetic seal-ing as well as MAP technology, product quality can be preserved and the amount of added preservatives can be reduced while extending food´s shelf life at the time. This also protects brand reputation, improves customer loyalty and offers higher sales potential.

Protection from oxygen, water and lightAfter the packaging process food shall be preserved for a long time. Depending on the product features, it is necessary to ensure protection

6 | packazine News Facts & Trends

Kenafric is a true success story. Founded more than 25 years ago as a small family business in East Africa, the company has grown into an award-winning and market leading manufacturer across several different industries. Initially dedicated to footwear manufacturing, the company soon entered the confectionery market with a plant solely focused on candy production. Based in Nairobi, Kenya, Kenafric currently counts approximately

1500 employees, making it one of the main players in Africa’s confectionery industry. Operating on the principle of always staying one step ahead, Kenafric has been a partner of Bosch Packaging Tech-nology for years. This partnership helps the company ensure that its products are produced and packaged with the latest technologies, fostering innovation, customer satisfaction and growth.

In particular, when one of Kenafric’s recently launched product brands grew increasingly popular, it sought an energy-efficient processing and packaging line that could help it meet the growing demand.

Fresh and sweet new productsKenafric is the largest manufacturer of confectionery in East and Central Africa, producing a large selection of candy

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First chewing gum line of its kind in Africa for award-winning manufacturer

products including hard boiled, bubble gum, lollipops and toffees. Amongst its top selling brands are its cream yoghurt ice-cream flavored lollipops and Zing, a bubble gum.Traditionally, confectionery products in the region were simple sugary recipes that were not branded. However, consumer demands have significantly changed during the last couple of years, with increasing requests for better quality products. Future-minded producers are building a reputation for quality and developing brand loyalty. Kenafric is one of the pioneers in terms of branding in the market and devoted to fulfilling consumer demand for high quality products. The company recently launched its premium chewing gum brand “Fresh”, a range of squared dragées, which are bite-sized, colorful gums with a hard outer shell coated with sugar. This new chewing gum line features the flavors of peppermint, spearmint, menthol and fruit flavours. The distinct packaging stands out on shelves across Africa. Although the range was only launched

in 2012, it is already very popular and considered one of the favorites in the African market.

Conserving energyKenafric is committed to sustainable growth and is focused on the implemen-tation of energy-efficient measures and technologies. Due to these efforts, it is the only company in East Africa that has been awarded the Energy Management award (EMA) by the Kenya Association of Manufacturers for three consecutive

years. This annual award has recognized Kenafric for achieving significant reduction of its energy consumption year on year. In line with this strategy, one of Kenafric’s main objectives when searching for new equipment to be integrated in its produc-tion plant was to find processing and packaging machinery with very low energy consumption rates. With this challenge in mind, the company turned to its long-time partner Bosch, who delivered reliable quality equipment with

8 | packazine Customers & Markets Food and Confectionery

Only one year after the introduction, the new premium

chewing gum brand “Fresh” celebrates a great success in

the African market.

With the help of the new line from Bosch, Kenafric

now produces more than one ton of chewing

gum per hour.

the desired energy efficiency levels. “Bosch has been a reliable partner for us since the late 1990s and supported our company in realizing new ideas and launching new products,” said Kirtan Shah, managing director, Kenafric.

It’s a wrap! When planning its new line layout, Kenafric needed a new customized line that could not only meet its energy con-sumption requirements, but also could produce large amounts of product with low downtime rates in order to meet the increasing market demand.Bosch’s know-how allowed the company to develop a proprietary design of the production line, including both process-ing and packaging equipment that enables Kenafric to reduce its energy consumption and produce high quality products. The processing line consists of a forming extruder WEF 1020, a rolling and scoring line WWK 0401, a cooling tunnel WTC 1500 and an in-line breaking drum WOB 0700. Bosch’s rolling and scoring line at Kenafric was the first of their kind in Kenya as well as in the entire East Africa in terms of low energy consumption.During the first processing stage, the gum mass is fed into the forming extrud-

er WEF 1020. Thanks to their dual drive technology, the integrated feeding rollers transfer the mass into the extruding screws at a speed optimized for the pro-cessed product to ensure high quality. The extruding screws transport the product to the extruder head, generating the adequate pressure required to from the gum mass into an endless rope. At the rolling and scoring unit WWK 0401, the mass is then formed into sheets. In the cooling tunnel WTC 1500, the product sheets are cooled down to a temperature suitable for further processing in the inline breaking drum WOB 0700 where the chewing gum sheets are separated into individual pellets. The continuous production process ensures the chewing gum is produced with equally high quality. In the last production stage, rotation of the breaking drum carefully crushes the sheets into squared dragées. After having been sugar coated, the dragées are transported to various BVK 2000 A Miniwrap flow wrapping machines that package the gums with speeds up to 2 000 pieces per minute. The primary packaged dragées are further packaged into pillow bags using the SVE 2515 AR vertical form, fill and seal machine. Thanks to the fully automated processing

and packaging solution, Kenafric reduced the risk of contamination during the production process which contributes to the high quality of the product.

Sweet horizons With Bosch’s customized line in action, Kenafric is currently able to produce over one ton of chewing gum per hour non-stop while meeting the company guidelines in terms of energy consump-tion. “Bosch contributed to our success-ful history and is part of our flourishing future. The new line is helping us to maintain our leading position in the African confectionery market,” said Shah.Thanks to the success of the new customized line, Kenafric is planning on implementing a second line to increase the production volumes of its famous chewing gum. For more information please contact:

Frank Jansen

Phone: +49 2162 248 452


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Founded in 1869 and famous for ketchup, the product portfolio of Heinz also includes sauces, ready meals and infant nutrition reaching 200 countries. In Italy its iconic Plasmon® brand of baby food has fed multiple generations since 1902. The brand has grown from 20 products to over 230 and climbed to the top of the Italian market. As babies are among the most vulnerable and delicate consumers, their food must

be packaged according to extremely strict safety and hygiene standards. As a result, the European baby food market has been embracing aseptic packaging, which enables hygienic, shelf-stable products that are also highly nutritious and fresh tasting. Aseptic packaging allows products to be stored at ambient temperatures without the need for preservatives, retort processing or refrigeration.

To maintain its top position, Heinz strategically decided to enter the aseptic sector with the popular Plasmon® brand, as well as its Merenda and Sapori di Natura™ baby desserts. Heinz turned to Bosch Packaging Technology, which supplied the complete line including secondary packaging, being the first aseptic thermoform line in the Italian baby food market.

Good for babies, good for Mother Earth

Bosch supported Heinz in developing an award-winning pack style for its baby food


or preservatives, it is critical to retain the food´s original taste and appear-ance. The traditional glass jars involved extensive cooking at lower temperatures and vacuum sealing potentially affecting the flavor and color. The aseptic process, by contrast, protects product freshness and nutritional content while avoiding discoloration of the food product and maintaining the highest hygiene levels. This allows babies to safely savor the first meals of their lives. Having worked with Bosch for 20 years on a variety of products, Heinz devel-oped a solid trust in Bosch’s packaging solutions. Bosch’s TFA 4830, a state-of-the-art aseptic thermoform fill and seal machine, offers the flexibility to pack the aseptically-processed food into 80-, 100- or 120-gram plastic pots. Not only is this more cost-effective than incorporating multiple machines for different package sizes, but it also allows for a decreased footprint. At Heinz, one film reel produces 67 400 80-gram containers. To create the pot, a plastic film is heated and formed by a mold. They are then filled by the machine’s full-metal piston fillers before being sealed with a plastic lid to protect against contaminants and tampering. An additional reclosable

lid is placed on top so the pot can be resealed and reused.

Safety firstThe TFA 4830 offers exceptionally high levels of safety compared to other solutions available in the industry, key to Heinz deciding to partner with Bosch. While the market standard is one fault for every 10 000 products, upon Heinz’s request, Bosch committed to one fault per 30 000 products – three times the safety over competing solutions. Addi-tional safety elements included process optimized features such as an automatic shut-off of the machine, if the cabin drops to ambient pressure.At 24 pots per stroke and 25 strokes per minute, the TFA 4830 produces 600 pots per minute. In addition, the machine features automatic label reel changes without needing to stop production, resulting in increased uptime. Additionally, the machine’s fillers produce highly accurate filling, vastly decreasing product waste. The new plas-tic material has an added safety feature compared with glass – it is unbreakable, addressing the need for safe packaging. This is an important buying criterion for parents.

Award-winning sustainabilityHeinz’s new aseptic process and packag-ing style generated such significant reductions in the company’s overall car-bon footprint and material usage that it won the Oscar de l‘Emballage (“Oscar of Packaging”). Previously for the Plasmon® brand, two traditional glass jars were packaged into a single carton. Bosch’s new solution uses lighter-weight plastic pots, allowing two 80-gram pots to be stacked on two others and wrapped into one carton. Not only did the aseptic pro-cess reduce carbon dioxide emissions by 50 percent, but the new plastic pots are 89 percent lighter than the original glass jars, which decreases fuel needed for shipping. The pots are also reusable and 100-percent recyclable, making all mothers smile, especially Mother Earth.

Partners in packagingThe facility in Latina, Italy, which is Heinz’s second largest European plant, producing 1.2 million jars of baby food per day and mainly exports to the United Kingdom, with plans to grow its reach to Russia and Australia. As Plasmon® uses only natural ingre-dients such as fresh fruit and selected lean meats with no artificial sweeteners

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Heinz also selected Bosch’s shuttle car-rier and Elematic cup handling system, sleever and case packer for speedy secondary packaging. The Elematic 1000 SL packages the filled and sealed pots into carton sleeves with three different cup heights and various sleeve configurations. Then, the Elematic 6000 EFC places the cartons into wraparound cases. With Bosch as a single-source supplier, Heinz had one point of contact for the entire packaging line, which saved time on project management as needed.

Mom knows bestItalian mothers have particular cultural demands with baby food. Instead of pur-chasing a ready-made meal, they prefer to have vegetables, meat and other ingredients packaged separately so that

they can mix them themselves and pre-pare the meal for the baby. This required a different approach to production by using smaller pack styles with more vari-ety, and the TFA 4830’s flexibility allows Heinz to easily adapt to market needs. In addition, mothers reported that upon tasting the aseptically packaged food before feeding their babies, they noticed that it now tasted like fresh food. The TFA 4830 also incorporates a nitrogen gas flushing system for the cup headspace in the lid-sealing area. The system was specifically tailored to meet Heinz’s needs. This guarantees oxygen levels of less than one percent, ensuring that meat retains its red color and does not brown over time. This gives parents confidence in freshness and solidified Heinz’s top position in the Italian baby food market.

“This was a win-win situation not only for our profitability, but also for increasing our sustainability efforts and reinforcing our leadership position as innovators in the baby food packaging industry in Italy,” said Massimo Zonca, group leader for Global Packaging Innovation and Execution at Heinz. “Now other Heinz affiliates are considering replicating this success by incorporating the same technology.”


Robert Fesl

Phone: +49 711 811 57229



With its TFA 4830 Bosch guarantees an error ratio of 1:30 000 for the Heinz’s products, excelling the market standard by 200 percent.

The path to success

machine to boost output. The delicate and sticky granola bars often broke on the existing machine, jamming the system and necessitating frequent down-time for cleaning. Nature’s Path partnered with Bosch Packaging Systems and Charles Downer & Co., Ltd., a manufacturers’ represen-tative, for a completely reengineered bar packaging line for its Blaine, Washington, facility that doubled processing speed and quadrupled run time, resulting in up to six times the output of the previous solution.

Seamless transitionTo find the best solution for the challeng-ing rice and granola bars, Nature’s Path

Since its beginnings in 1985, Nature’s Path has prided itself on providing a vari-ety of 100 percent organic food, includ-ing cereals and granola bars. Based in Richmond, British Columbia, Canada, the family-owned company produces deli-cious products that are both FairtradeTM and non-genetically modified organism (GMO)-certified. Health-conscious consumers of all ages caught on to the company´s delicious and nutritious products – so much that demand began to outpace production. In particular, Nature’s Path granola and rice bars, such as the Peanut ChocoTM Granola Bars and Chocolate Crispy Rice Bars, became so popular that the com-pany needed to upgrade its packaging

approached several packaging compa-nies and surveyed their solutions, includ-ing Bosch. Nature’s Path had previously worked with Bosch to wrap its signature toaster pastries using a Doboy flow wrapper. It became clear that Bosch’s bar packaging line provided the most advantageous and efficient system. Nature’s Path’s previous solution fea-tured one wrapper, cartoner and case packer with manual palletizing. The new system, a Bosch bar packaging line, is designed as a single, seamless system rather than a chain of machines. To achieve a reliable and optimized produc-tion flow, the speeds of all components in the bar packaging line are balanced to eliminate bottlenecks and minimize downtime. As a result, the completely automated line runs at speeds up to 500 products per minute – more than double as of the previous solution. In addition, the new wrapping material dimensions conform closer to the actual product, reducing material needed and resulting in a 6 percent saving on pri-mary wrapping and tri-seal carton mate-rials.The bar packaging line has been so

Bosch helps Nature’s Path double output of its organic rice and granola bars

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successful that Nature’s Path has plans to add a second leg to further increase production.“The bar packaging line is meeting all original design specifications,” said John Oucharek, director of engineering at Nature’s Path.

Sticky situationThe rice and granola bars’ gooey and sticky characteristics are treasured by consumers but present particular pack-aging challenges. Because the product is so sticky and prone to breakage, produc-tion on the previous solution had to be halted every two to three hours due to extensive build-up of damaged products. The new bar packaging line’s non-con-tact infeed guides the product with mini-mal breakage, allowing the system to run at double the speed than the old line and up to eight hours before cleaning. This quadruples production time and the output by up to factor six.As Nature’s Path packages different products on the same system, easy and thorough cleaning was of paramount importance to eliminate all traces of pos-

sibly allergy-causing ingredients. The bar packaging line features standardized parts and components, as well as high visibility and accessibility, that simplify cleaning and maintenance. All belts, endrollers, catch pans and scrapers can be removed without tools for expedited cleaning. In addition, the bar packaging line offers the flexibility needed for speedy product changeovers.

Smooth operatorWith the fully-automated bar packaging line, Nature’s Path was able to reduce manpower from eight operators to two, allowing the company to redirect work-ers to higher-skilled tasks. All interfaces and components, including the distribu-tion station, accumulator, flow wrapper and toploader, feature a uniform design. This makes operation of the entire line as simple as operating a single machine and reduces the risk of operator errors, which can cause lengthy and costly pro-duction stoppages. To ensure that the line functions with maximum overall equipment effectiveness (OEE), Bosch trained the operators during installation.

The primary wrapping system features product inspection components and an evacuation conveyor that ensures that only top quality products reach the pack-aging system. The bars travel along a conveyor that facilitates constant prod-uct feeding, and the distribution-gentle direct (DGD) crossfeed station, which offers several cleaning and maintenance advantages, such as belt changes in under 20 minutes, tool-less disassembly in under five minutes, and easy access for allergen clean-up. This allows Nature’s Path to achieve maximum uptime and the highest food safety stan-dards.Each product then goes through the product alignment, inspection and rejec-tion unit that measures length, width and height to ensure that each bar meets required standards. The bars then pass through the non-contact double pullnose inline feeder (FBPC), which guides them individually into the carrier chain of the flow wrapper and is the key to prevent-ing products from sticking together, which would result in faulty indexing and halt production.


The non-contact feeding solution (FBPC) is a unique patented solution that runs successfully on sticky and chewy products. The bars then travel to the Sigpack HCM flow wrapper, an electronically con-trolled servo-wrapper equipped with coldseal film. The Sigpack HCM features an automatic reel splicer that allows operators to simply place a new reel onto the splicer while the machine is running.

Speedy cartoning and retail-ready packagingThe Sigpack cartoning system takes over the primary packaged bars using a vac-uum wheel and positions the products continuously into the grouping module. The carton forming machine Sigpack TTF

moulds the carton blank cuts. Guided to the high speed toploader Sigpack TTL, the moulded cartons are loaded with the primary packaged bars according to programmable settings. The succeeding TTC carton closing machine closed them by gluing the flaps in a tri-seal style. The cartoning system can package up to 120 cartons per minute and features no change parts for easy and fast change-over. Nature’s Path also selected Bosch’s Elematic 3000S for speedy retail-ready packaging that resulted in a 15-percent reduction on corrugated case material. The operator simply programs format selection, position, speed, timing and glue position via a touch panel. Addition-ally, the Elematic 3000S can package up to 25 cases per minute and is also able

to create 35 different styles of cases, allowing for point-of-sale differentiation. Nature’s Path has been very happy with the complete bar packaging system and is positioned to further accelerate production to 750 products per minute. “Bosch’s complete line solution was perfect for increasing production of these challenging bar products,” said Oucharek. “With Bosch as a single source supplier, everything is simplified – from installation throughout produc-tion.”


Klaus Haebig

Phone: +41 58 674 6613


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Foods Inc. Creating delicious moments of joy in 165 countries, Mondelēz Inter-national is a world leader in chocolate, biscuits, gum, candy, cheese, coffee and powdered beverages, with brands such as Cadbury and Milka chocolate, Jacobs coffee, LU and Oreo biscuits. With an array of well-known brands whose pedigrees stretch back more than a hundred years, Mondelēz International is a world leader in the manufacture of cheese. In its plant in Namur, Belgium, the company produces a range of foods including processed cheeses destined for European retailers. In the past, Mondelēz International pro-duced multi-taste packages of processed cheese. The line had been set-up with different tanks and pipes for each flavor of cheese being placed in the pack. As this product had been switched to single flavor packages, the company found that it was losing in efficiency. Producing

single flavor packs on a line designed and optimized for multi flavor packs required extensive cleaning for the redundant pipes. The existing lines, with four Bosch ML4 processing systems which both produce and package the cheese, needed to be adapted to the new production requirements.

Wheying up the needs of the revamped lineBosch recommended the installation of a range of new mechatronic dosing units compatible with the lines’ existing structure, and easy to integrate into a central quality and product control system. The new machinery is closed, as opposed to the previous open design of the dosing units, to reduce contami-nation risks and increase dosing accu-racy while improving product quality. Another important factor was Mondelēz International’s ambitious and extensive

Mondelēz International revamps its processed cheese lines to gain productivity

Time is money, and cheese

To keep their brands relevant and entic-ing, manufacturers of consumer products must frequently consider changing tastes, sizes, shapes and packaging. This may entail changes to processing and packag-ing lines, which need to be done effi-ciently to ensure a minimum of downtime, and a maximum return on investment.One major producer of processed cheese, Mondelēz International (formerly known as Kraft Foods Europe), has taken the opportunity to work closely with Bosch Packaging Technology, to increase efficiency on some production lines. Based on the needs of the manufacturer, Bosch delivered a highly efficient and tailored cheese processing system with gains in uptime and operational control.

A new format for a familiar brandLaunched on October 1, 2012, Mondelēz International comprises the global snack-ing and food brands of the former Kraft


Total Productive Maintenance (TPM) pro-gram, which improves machine availabil-ity through the empowerment of line operators who get an extensive training. As part of the modernization project, Bosch carried out trainings, so each operator is trained to “own” his machine and perform day-to-day maintenance tasks to decrease downtime.

Building the right solutionIt was essential for Mondelēz Interna-tional that any improvements are com-pleted quickly. Line managers from the Namur site and the engineers from Bosch were looking for ways of reducing the forecasted downtime for the line revamp from a fortnight to one week. This was achieved by increasing the availability of the mechanics working on installing the new technology, through changes to their work hours and shifts. To test and adapt the equipment Bosch

performed a range of factory acceptance tests in their facilities, to make sure the new dosing units could be fully inte-grated and would meet Mondelēz Inter-national’s requirements. As the units are now closed, Bosch added windows to the equipment, enabling line operators to inspect the quality of the cheese inside as well as dosing performance.

Savoring the benefitsIn addition, Bosch encouraged the com-pany to integrate five dosing units for the four production lines. This way all four processing lines can be in operation while one dosing unit is cleaned, cutting downtime due to cleaning processes considerably. Mauro Del Priore, the technical project manager at Mondelēz International in charge of the lines adds, “Our operators, while initially cautious, have really come to appreciate the upgraded machines.”

Partners for successKey to the success of the line upgrade was the close and productive partner-ship between Bosch and Mondelēz Inter-national. “This project was a frank success, with our lines back up and running in record time. We achieved this with Bosch’s help, as they understood our need for heightened efficiency and productivity,” says Del Priore. “The modified system has given our line the boost necessary to help us continue to meet public demand.”


Gert-Jan de Jong

Phone: +31 495 574 365


The Sapal ML4 wrapping and dosing system for processed cheese portions is specially designed for high-speed perfor-mance under peak hygienic standards. Various shapes can be conditioned: triangular, square, rectangular. Outputs up to 540 portions per minute can be achieved.

The linear construction with completely closed casing features automatic lubrication of the drive elements operating simulta-neously on four tracks. For packaging, the aluminium foil fl at blanks are cut off individually by cutting devices, the optional tear-open strips and labels are sealed or alternatively glued on the foil cut-offs. Then, shells are die-formed on four tracks and fi lled by the newly designed liquid cheese mecatronic dos-

ing system. This dosing unit releases the liquid cheese evenly corresponding to the product volume. It allows independent weight adjustment per track or general for all tracks. A device cuts and deposits the foil covers above the fi lled shells in order to hermetically seal the portions. This all is based on latest PLC technology.

For triangular portions a grouping station is available to achieve circular layers of six, eight or twelve portions which could be placed in a fully automatic Sapal boxing unit. The equipment can also be incorporated into systems using other Bosch components like fl ow wrappers or case packers.

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Endangered Species ChocolateTM does not only measure success by dollar signs. As evidenced by its name, the pre-mium chocolate company headquartered in Indianapolis, Indiana, donates 10 per-cent of its net profits to species and habitat conservation efforts. Its ethical trade criteria ensure that its premium cacao comes from farm cooperatives that foster community development and provide humane working conditions and fair wages for all cacao farmers. In addi-tion, the company carefully sources only the highest quality organic and all-natu-ral ingredients from farmers that prac-tice sustainable farming. As a result, Endangered Species prides itself on being a successful business that puts fewer chemicals into the earth, protects rainforests and provides solid jobs. The result is delicious and ethically-pro-duced chocolate that has quickly grown in popularity and allowed the company to experience tremendous growth. Recently, more and more consumers

were craving its 0.35-ounce Organic Chocolate Squares, known as Chimp Mints and Bug Bites, to the point where demand began outpacing production. Endangered Species reached out to its partner Bosch Packaging Technology for an automated solution that more than tripled output.

Partners in packagingSince its humble beginnings in 1993, Endangered Species has relied on Bosch’s Doboy Stratus, an entry level and compact horizontal flow wrapper, to package its beloved Chimp Mints and Bug Bites. The partnership has allowed the company to rapidly extend its distri-bution reach, which now covers the United States and Canada. Since going national in 2005, the company has more than tripled in size. To meet increasing demand, Endangered Species worked closely with its local Bosch agent Keith Goodhart of RPMI Packaging Inc., and decided to upgrade to Bosch’s Pack 401

horizontal flow wrapper integrated with a Pack Feeder 4 six belt feeder, a system capable of automated product transfer and simplified cleaning and mainte-nance.While the previous solution required that the chocolate squares be manually transferred from their molds to the primary packaging machine, the Pack Feeder 4 directs the chocolates from the mold line to the horizontal flow wrapper without human intervention. This speeds up production and decreases operator requirements from six to one, which allows the company to redirect labor to higher skilled positions. The Pack 401 runs at film speeds up to 80 meters per minute and features self-centering film reel holders that enable easy and quick film changeover. The machine automatically tracks and aligns the film to create consistent package quality and seals for the chocolates. Additionally, two spindles automatically splice film rolls with integrated cutting


Charitable chocolate company finds sweet success

Bosch helps Endangered Species ChocolateTM accelerate production

knives, allowing Endangered Species to run a full eight-hour shift with little to no downtime. As a result, the automated solution accelerated production from 120 pieces per minute to 400 pieces per minute, with the potential for output levels up to 550 products per minute. “The Pack 401 wraps our products faster than we can currently produce them,” says Bryan Fuller, director of operations, Endan-gered Species. “This positions us for our anticipated growth over the next few years.”The Bosch flow wrapper ensures that the tiles are correctly oriented before being wrapped, which decreases inade-quately packaged products. The previ-ous solution necessitated that defective packaging be manually sorted and dis-carded. The Pack 401 features sensors that automatically detect and reject inadequate products and packaging, such as empty packages, uncut pack-ages, or packages with film splices,

which increases efficiency and saves labor costs. “Our conservation mission is the core of our organization and we fully trust that Bosch’s technology will produce results,” Fuller adds. “Higher profits and reduced waste mean more donations to our not-for-profit partners.”

Keeping it cleanEndangered Species also sought a machine with simplified cleaning and maintenance to ensure product safety and remove all traces of allergy-causing ingredients, which is especially impor-tant when producing different products on the same machine. “The Pack 401 is an expertly planned machine – every section is easy to access and clean,” explains Fuller. Crumb trays on the feeder can be removed and emptied during production and all belts and deck plates can quickly be removed without tools, making cleaning fast and easy.

Holistic sustainabilityNot only does the Pack 401 generate higher profits that increase donations to the company’s charitable causes, but it

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achieves additional sustainable benefits. When the products were manually trans-ferred to the wrapper, the tiles had to be placed on FDA-approved cardboard sheets and then topped with FDA-approved foam to be stacked without damaging the chocolates. The machines automated feeder eliminates the need for these materials, which cuts down on waste and fuel needed to ship them to landfills. Endangered Species also uses packag-ing materials that are Forest Steward-ship Council (FSC) approved, with

paper wrappers composed of recycled content and printed with environmen-tally friendly water-based inks. Sustain-ability is ingrained in the entire com-pany, from resourcing raw materials to incorporating the most environmentally-friendly processing and packaging prac-tices available.“We always enjoy helping our customers reach their production goals and it’s even sweeter when this also benefits important causes,” says Paul Garms, product manager, Bosch Packaging Technology.

“I’ve wanted this machine for a very long time because Bosch understands our organization and packaging like none other,” says Fuller. “When demand grew to the point of needing increased effi-ciency, it was an easy decision to make and we’ll likely acquire a second Pack 401 soon.”


Paul Garms

Phone: +1 715 243-2503



Since Endangered Species works with the horizontal flow wrapper Pack 401 from Bosch, the production increased from 120 to 400 packages per minute.

Fifty years of successfully providing top-quality mueslis, cornflakes, muesli bars, jellies and confectionery to leading Polish and international retailers and dis-tributors is a great achievement. Head-quartered in Otmuchow, with additional production facilities in southern Poland and a total of 840 employees, the Polish

confectioner Otmuchow SA manufac-tures sweets and savory snacks that feature natural ingredients and fine flavor additives. Customers worldwide enjoy Otmuchow’s high-quality products and competitive prices. With its popular products, Otmuchow’s top priority is increasing capacity while

maintaining product quality in accor-dance with the safety and health stan-dards of the European Union. In order to meet its goals of maximizing productivity and efficient production with the most modern processing and packaging tech-nologies available, Otmuchow has bene-fitted from its long partnership with

Otmuchow triples output of jelly production with turnkey solution

Polish confectionery manufacturer benefits from Bosch’s processing and packaging expertise

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Bosch Packaging Technology. When it came time to upgrade its jelly processing and packaging line, Otmuchow again partnered with Bosch as its single source solution provider and acquired a com-plete line of Bosch machines for every step of the production process, from the dissolving of ingredients through to the final packaging of the jelly products. Jacek Piech, technical director at Otmuchow is proud to announce: “Thanks to this decision, we saw a signifi-cant increase in efficiency and more than tripled output from 800 kilograms per hour to 2500 kilograms per hour, while meeting the highest quality standards.” From gelatine to gummy bears – flexibility combined with precisionFor its production of jelly products including double-layered and filled jel-lies, Otmuchow relies on a full range of sophisticated Bosch machines that dis-solve, dose and mix the jelly ingredients. The Gelatine Dissolving Unit BLS 0300 CA ensures an uninterrupted delivery of gelatine to the production line. The basic

jelly mass is mixed in the Gravomat BDS 0116 AD, a computer-controlled weighing, dosing and mixing system that guarantees the highest formula consis-tency. The Gravomat’s recipe manage-ment for up to 200 recipes allows for fast product changeovers – a perfect fit for Otmuchow and its wide variety of jelly products. Otmuchow also integrated a second Gravomat into the line for dosing and mixing of vitamin premixes. Once the ingredients for the basic jelly mass are mixed, they are loaded into the Rapidsolver BLK 2500 BR unit, an advancement of Bosch’s pressure dis-solver specifically designed for gummy and jelly products. The mass is dissolved under adjustable counter-pressure and then conducted into the integrated vac-uum chamber, where it is cooled to the processing temperature. The BLK’s design offers excellent heat transmission and high-blending quality, preventing uneven distribution of phase flows, also known as maldistribution effects.In the next step, additives such as color-ing, flavoring, fruit juices, and vitamins

are added to the basic jelly mass. This requires precise dosing and mixing for cost and quality reasons. The gravimetric mixing and dosing machine BMG 0010 A offers an ideal solution. Otmuchow also searched for a solution for its filled jelly products and found this with Bosch’s universal batch cooker BKS used to pro-duce the filling mass. For its double-layer jellies consisting of a clear and a foam layer, the company integrated the contin-uous aerating machine BBK into its pro-duction line to achieve a perfect texture of the foam.

Keeping gummy bears in shapeWith its previous equipment, Otmuchow sometimes faced challenges such as small bubbles on the back of the jelly mass or gummy bears with three eyes – quite the aberration. However, these have been successfully avoided since Otmuchow switched to Bosch’s latest depositing technology. To be deposited, the mixed ready mass is fed into the Makat Mogul HLM 35 RS, a high-performance starch molding


machine. The jelly form is pre-pressed into trays filled with starch by servo-driven printing presses before the mogul plant´s depositors mold the mass into the forms. The trays are then stacked and transported to the ripening room. Coming from there, they are fed back into the mogul plant, the solidified jellies are removed, de-starched and cleaned. The starch that has been removed with the jellies is reprocessed in the TF 8000 L before it goes back into the mogul plant. One of the advantages of the TF 8000 L lies in its adjustable dwell time, which effectively removes moisture at product-conserving temperatures. As a result, products obtain a perfect surface and texture.The mogul plant ensures exact weight, shape and coloring distribution. For flexibility, different jellies like striped, double-layered and filled ones can be handled. The integrated Makat Roto-Step advancing system is used which suffers less wear and gives higher precision due to individual tray movement. For special finishes, Otmuchow uses a Makat sugar

coating drum to coat articles with a wide range of crystal sugars, and a Makat oiling drum to generate a constant oil film on the surface of products.

Packaged to perfectionIn deciding on a packaging system, Otmuchow’s key requirements were a packaging solution that could not only handle a wide range of product formats, but also ensure dosing accuracy. “While overfilling leads to losses for the manu-facturer, underfilling comes at the expense of the customer. Bosch pro-vided an ideal packaging solution: the SVE 2515 AR, a continuously operating vertical form, fill and seal machine. Jacek Piech, technical director at Otmuchow explains further, “The machine’s low overall height allows for speedy changeovers, which is important for us, as our jelly products come in many different sizes.” Designed to pack-age free flowing, loose products, the SVE features a weigher which can be easily adjusted to accommodate different sizes. Otmuchow is using two SVEs for

packaging its sweets into pillow bags. Protecting the high quality of Otmuchow’s jelly products and ensuring accurate dosing, the machine’s servomotor- controlled movement of the sealing jaws guarantees reliable performance and strong sealing seams.

Maximizing resultsRelying on Bosch as the single source solution provider for its jelly production and processing line, Otmuchow has been able to increase output by more than 200 percent while maintaining the high-est quality standards. Bosch’s optimized cooking, mixing and dosing processes, in addition to accurate depositing and packaging technologies have helped Otmuchow to deliver the high quality that customers expect of their jellies.


Frank Jansen

Phone: +49 2162 248 452


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Events Food 2013

Events Pharma2013

Date Event Location Branch

06.11. – 06.14.2013 FOOMA Japan Tokyo Food

06.12. – 06.15.2013 ProPak Asia Bangkok General

06.18. – 06.21.2013 EXPO PACK Mexico Mexico City General

06.25. – 06.28.2013 Fispal Tecnologia São Paulo General

07.17. – 07.19.2013 ProPak China Shanghai Food

08.30. – 09.01.2013 Foodpro Chennai Food

09.05. – 09.08.2013 Ipack Turkey Istanbul Food

09.13. – 09.15.2013 China Dairy Industry Show Fuzhou Food

09.23. – 09.25.2013 PackExpo International Las Vegas General

09.24. – 09.26.2013 FachPack Nuremberg General

10.02. – 10.03.2013 Empack Brussels Food

10.06. – 10.09.2013 IBIE Int. Baking Industry Exposition Las Vegas Food

10.06. – 10.09.2013 PackPlus New Delhi Food

10.07. – 10.11.2013 Agroprodmash Moscow Food

10.15. – 10.18.2013 Japan Pack Tokyo Food

10.30. – 11.02.2013 Allpack Indonesia Jakarta General

11.07. – 11.09.2013 MAFEX Maghreb Food Exhibition Casablanca Food

11.26. – 11.28.2013 Food Processing & Packaging Exposyum Nairobi Food

12.10. – 12.12.2013 Sweet & Snack Processing & Packaging Ahmedabad Food

DateEventLocationBranch

06.06. – 06.07.2013European Lab Automation HamburgPharma

06.12. – 06.15.2013ProPak AsiaBangkokGeneral

06.18. – 06.21.2013EXPO PACK MexicoMexico CityGeneral

06.25. – 06.27.2013CPhl, P-Mec ChinaShanghaiPharma

06.25. – 06.28.2013Fispal TecnologiaSão PauloGeneral

07.10. – 07.12.2013INTERPHEX JAPANTokyoPharma

09.23. – 09.25.2013PackExpo InternationalLas VegasGeneral

09.24. – 09.26.2013FachPackNurembergGeneral

10.07. – 10.08.2013PDA Visual Inspection ForumBethesdaPharma

10.15. – 10.17.2013A3P CongressBiarritzPharma

10.22. – 10.24.2013CPhl, P-Mec WorldwideFrankfurtPharma

10.29. – 11.01.2013China PharmShanghaiPharma

10.30. – 11.02.2013Allpack IndonesiaJakartaGeneral

11.05. – 11.06.2013PDA Pre-filled Syringes & Injection Devices BaselPharma

11.10. – 11.14.2013AAPS Annual MeetingSan AntonioPharma

11.14. – 11.15.2013SupplySide WestLas VegasPharma

11.25. – 11.28.2013PharmTechMoscowPharma

12.03. – 12.05.2013CPhl, P-Mec IndiaMumbaiPharma 11/22-11/25/10

24 | packazine Events 2013

(subject to alterations)

(subject to alterations)

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