Food & Confectionery · Issue 2011 packazine · Food & Confectionery · Issue 2011 Nestlé |...

Food & Confectionery · Issue 2011

Nestlé | Chocolate Wafers from DubaiChocolat Frey | Rapid and Efficient Spare Parts Logistics Online Paterson Arran | Automated Biscuit Handling with Delta Robotics

packazine

2 | packazine Table of Contents | Editorial

www.boschpackaging.com [email protected]

News

Facts & Trends0406

07

Save Food | Cut WasteInternational Packaging Institute | Bosch Packaging Technology Committed to Further Education125 Years Bosch | 2011 Year of Anniversary

Customers & Markets

Food & Confectionery08 Nestlé | Chocolate Wafers from Dubai

11 Chocolat Frey | The E-Portal Keeps Things Sweet

13 Paterson Arran | Automated Biscuit Handling with a Gentle Touch

16 Ülker | Expansion Is All Wrapped Up

18 Unilever | Smart and Sustainable Packaging of Mashed Potatoes

20 Humana | Baby Food Production on Bosch Aseptic Line

Events

22 Events 2011

CoverHigh Performance Packaging

of Enrobed Wafer Bars

08 11 13

Customer magazine of the Packaging Technology Product DivisionRobert Bosch GmbH

Editor in ChiefCentral MarketingChristian Bosshard, Johanna BauerTelephone +41 (0)58 [email protected]

DesignCentral Marketing, Karin Schmückle

PhotosOtlinghaus Fotodesign; CN-Photography; Bosch Packaging Technology

PublisherProduct Division Management, Stuttgarter Straße 130, D-71332 Waiblingen

© Copyright · Packaging Technology Product Division Robert Bosch GmbH

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

Imprint

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Table of Contents

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Dear Readers,

In the year of Interpack 2011, Bosch has two reasons to celebrate: the company’s 125th anniversary, as well as the 150th birthday of its founder. This provides us with

a more than good enough reason to review the past – our aim is to connect our origins with our future. Bosch can look back on an eventful, as well as a powerful, history, which gives us an incentive for new and, above all, beneficial achievements.

Bosch Packaging Technology’s history dates back to 1861. The Hesser Company was founded that year and was later to become part of the Bosch family. In 2011, Bosch Packaging Technology can therefore look back on 150 years of packaging know-how. As early as the 1960s, Bosch was able to secure a powerful market

position and industry leaders like Strunck, Hamac-Hansella and Höfliger & Karg have joined the Bosch Group since. Under the Bosch umbrella, the tradition, experience and knowledge of various product brands are united, including well-known names like Demaurex, Doboy, Elematic, Makat, Moeller & Devicon, Pharmatec, Sapal, Schoeller-Bleckmann Medizintechnik, Sigpack, Tevopharm, Togum and Valicare.

However, without the trust of our customers, this anniversary would not have been possible. And, we will do everything we can to maintain and strengthen this trust over the next 125 years. We see ourselves in the tradition of Robert Bosch and his memorable phrase: “I would rather lose money than trust.” Now and in the future, creating quality products and keeping our promises take precedence over short-term gain and profit. In our sectors, good business relations are only possible by forming long-term partnerships.

We will be presenting our new products at Interpack, May 12–18 in Düsseldorf. Visit us in Hall 6. Let’s meet at Interpack to discuss your current and future projects. With our experience, we can offer the security of a competent and reliable partner for your machinery, from concept to commissioning.

Yours,

Friedbert Klefenz

18

Friedbert KlefenzPresident,

Bosch Packaging Technology

Editorial

4 | packazine News Facts & Trends

Cut Waste, Save FoodA new sustainability initiative highlights the positive impact of packaging

in reducing food waste.

Whilst it can be taken for granted that most people understand the link be-tween food waste and the CO2 emissions used to produce it, misconceptions remain over the scale and nature of the problem. Additionally, incorrect assump-tions surround the environmental impact of food packaging. The Save Food con-cept aims to set the record straight and highlight the huge potential of packaging in realizing sustainability gains.

A Worldwide IssueFood waste is a global challenge and in-cludes any food loss incurred during its

production, processing, transportation, distribution and consumption.

A significant amount of food waste is reported across the developed world, with Europe alone generating approxi-mately 245 million tons every year, according to Flexible Packaging Europe, the European forum for the flexible pack-aging industry. Losses at the consump-tion stage are especially high but, surprisingly, households account for a higher proportion of food waste than supermarkets, restaurants and the food processing industry combined. Poor

storage management, over-catering, the impact of busy lifestyles and an abun-dance of supermarket offers are just some influencing factors.

By contrast, in emerging markets, con-sumer waste is far lower, while waste in the supply chain is comparatively high. A primary cause of this is the widespread lack of appropriate processing and pack-aging technologies. In some countries, up to 50% of the total food produced is thought to be lost as a direct conse-quence of this scarcity of equipment1.

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The ConceptBy exploring how losses occur in each in-dividual stage of the food supply chain, we can determine the source of food waste and open the door for a broad range of innovative solutions. The Save Food initiative, which represents a com-ing-together of sustainable manufactur-ers with a shared social responsibility ethos, highlights how sustainable pack-aging is perhaps the most effective way of combating unnecessary consumer-cre-ated waste. For developing nations, it highlights how investments in basic packaging technologies are of fundamen-tal importance for producers to reduce waste at harvest and beyond.

The Role of PackagingIn emerging markets, even basic packag-ing innovations can save resources in the supply chain by preserving freshness and protecting food during transportation.

For example, food that perishes in just a few days without packaging – before even reaching the consumer – can last for weeks wrapped in only a thin layer of plastic film2.

On the other hand, tackling the problem of household waste in the developed world requires more focus on cutting-edge materials. Innovative packaging suppliers can help extend shelf life at home with resealable and other intelli-gent packaging solutions and by provid-ing useful information to consumers about storage and waste prevention. A range of portion sizes, easy-to-empty containers and vacuum packaging tech-niques also help combat the problem.

Positive PackagingPackaging manufacturers are, and must continue to be, at the forefront of food industry sustainability efforts. It is there-

fore of crucial importance that packaging is more widely and strongly promoted to be an integral part of the solution to re-duce excessive food waste and not al-lowed to be thought of as part of the problem.

For more information please contact:

Johanna Bauer

Phone +41 (0)58 674-7416

[email protected]

1 http://www.euroasiaindustry.com/page/142/

Food-packaging:-in-need-of-repackaging2 http://cr2010.tescoplc.com/environment/

waste- packaging-and-recycling/packaging.aspx

6 | packazine News Facts & Trends

In the packaging sector, comprehensive knowledge along the entire value chain has become extremely

important. Lifelong learning is also a fundamental factor for success in the packaging industry.

Bosch Packaging Technology has recognized the importance of this for years and is a committed

member of the IPI International Packaging Institute.

Bosch Packaging Technology Committed to Further Education

Bosch Packaging Technology provides its workforce with qualifications in the shape of targeted IPI further education modules. New associates take part in a special Bosch introductory seminar which facilitates their entry into the packaging industry. A further six-day technological seminar on “Packaging Machines” provides associates working in the technical sector with in-depth knowledge on the technologies used in the packaging machine industry.

Also available is an occupational Masters degree course, in which participants gain comprehensive knowledge about packaging materials, engineering and management over a two-year period. On completion of the Masters degree course, graduates are highly qualified to take on managerial responsibilities within the company.

IPI International Packaging Institute The IPI International Packaging Institute is a further education, networking and

service center for the packaging indus-try. It was established in 2004 by leading companies in the industry in cooperation with prominent universities.

The IPI’s further education program includes the world’s first “Master of Engineering in Packaging Technology” occupational degree course, a range of packaging technology seminars, as well as customer-specific education courses. The events organized by the IPI cover cutting-edge, industry-related topics and, in discussion sessions and during breaks, participants are encouraged to develop course content further and establish new contacts in the packaging industry.

Aside from its further education pro-gram, the IPI supports the packaging industry with technological and strategic advisory services.

For further information please contact:

IPI International Packaging Institute

Stephan Schüle

Phone +41 (0)52 675 51 51

[email protected]

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1861 Friedrich Hesser and Otto Geiger open a small workshop in Bad Cannstatt, near Stuttgart. Here, they produce envelope folding machines, which marked the beginning of the German packaging machine history.

1911 Hesser builds the first fully automatic package maker for coffee, soon followed by rotary and cutting machines as well as net weighers.

1958 Höfliger + Karg presents the first automatic capsule filling machine. It is the predecessor of the Bosch GKF and the much later Bosch GKF HiProTect.

1966 Bosch takes over Hamac-Hansella whose locations include Viersen and Weert.

1969 Bosch acquires Höfliger + Karg. 1970 Bosch concludes the develop-

ment of the first continuous cooker for hard candy and supplies the line to a major Swiss confectionery manu-facturer.

1980 Hesser develops the Aromafin V30 coffee valve.

1984 Takeover of Strunck. 1988 Introduction of the aseptic

film-based pillow pack for liquid and viscose products (SVA). At the same time, a high-performance coffee cream machine is launched with an output of 84 000 cups per minute.

1991 The first self-developed isolator

technology device (fixed wall isolator) for vial filling and sealing machines.

2002 Makat Candy Technology is taken over.

2003 Tevopharm as well as the Danish company Moeller & Devicon become part of Bosch.

2004 About 100 years after the com-pany was founded Sigpack joins Bosch and brings Demaurex, Sapal, Transver, Doboy and Sigpack/Singa-pore into the company.

2004 Valicare is established, a service provider in the field of qualification and validation of production and laboratory equipment for the pharma-ceutical and life science industries.

2004 Bosch Packaging Technology pools its service business in a single business unit. Bosch develops from a technology supplier into a proactive service provider.

2007 Pharmatec and SBM Schoeller-Bleckmann Medizintechnik are taken over.

2008 Bosch acquires Paal. 2008 Bosch Pouch Systems is estab-

lished. Pouch offers – as part of a comprehensive package – complete filling technology as well as the pack-aging material.

2009 Production start of packaging lines for Pharma liquid in China.

2010 With its Purified Water Plant

Pharmatec is now a one-stop provider of high-purity media.

2011 Bosch Packaging Technology Co. Ltd. Celebrates the 10th anniver-sary of its establishment in Hangzhou, China

For more information please visit our

website: www.boschpackaging.com

In 2011 Bosch has two reasons to celebrate: the company’s 125th

anniversary as well as the 150th birthday of its founder, Robert Bosch.

We will also reflect on 150 years of packaging history.

8 | packazine Customers & Markets Food and Confectionery

The TraditionYes, we do understand your astonish-ment reading the header, as you wouldn’t automatically associate choco-late wafers with a country in the Middle East. Nevertheless, for Nestlé, this area of the world has been a traditional market, as Paul Bulcke, Nestlé Chief Executive Officer, mentions in the official factory opening press announcement: ‘Nestlé has been present in the Middle East for 75 years, bringing meaningful value to society at large by sourcing locally, creating new local employment, offering nutritious products and helping in the further development of the region’This tradition also became one of the drivers to invest in a 136 million USD

manufacturing facility in Dubai, aiming to serve the Nestlé markets across the region. ‘By opening our new facility in Dubai – our regional headquarters – we will be closer to our consumers in the region and can better adapt our prod-ucts to their needs and preferences. The Middle East region is a very important part of Nestlé business and our contin-ued commitment and ongoing invest-ments demonstrate our confidence in the region’ as cited in the same Nestlé document.

The Project RequirementsFor the plan to produce flow wrapped 2 and 4 finger KitKat, Quantum and Chunky Wafer bars (including Multipack-

ing and cartoning) on two lines at very high output rates of 1 440 and 1 000 products/min in a new, dedicated plant, Nestlé from all the beginning on targeted to implement all new machinery and pro-cess in the plant with a lean strategy approach. In other words, it was impor-tant to ensure operational efficiency from the first day on. Bosch Packaging Technology, as one of the suppliers chosen to be part of this huge project, was committed to follow and support this approach in all disci-plines of the project.

Therefore, Nestlé’s supplier requirements were quite challenging, going from de-tailed technical specifications for manu-

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facturing of the equipment, including all third party components, up to detailed organizational life cycle planning at a very early stage. As a consequence, questions on lean start up during the on site commission-ing phase, operator training, continuous

production support and improvement, as well as spare parts sourcing have been thoroughly discussed and reviewed during the whole manufacturing process. No wonder the communication flow between the Nestlé and Bosch project teams was quite high, enabling the com-

panies to jointly define the criteria for common success for both partners.Following a discussion on training requirements at an early stage with Bosch’s dedicated training department, the teams decided to prepare this impor-tant launch by investing in intensive

Chocolate Wafers from Dubai . . .Nestlé decides on Bosch technology for achieving a lean

and efficient production in a new facility.


operator training, which was performed on an existing installation for the same product in central Europe, even prior to installation of the new machinery in Dubai.

The close joint project work also led to installing an embedded engineer helping with the introduction of the new technol-ogy during installation, the Factory Acceptance Test (FAT), on site commis-sioning and the Site Acceptance Test (SAT), and also later after the Bosch crew had left the site. The advantages of the E-Portal from Bosch spare parts ordering tool was another pillar for suc-cessful start up and autonomy in terms of preventive maintenance.

However, the path to common success has not always been smooth, and special

efforts had to be considered by both teams to run a new, locally sourced film material for multipack on the machines, following Nestlé’s goals to locally anchor the supply chain for new equipment. For this topic, the overall general good and close cooperation between the project teams contributed to identifying the right solution in the end.

The Plant InaugurationNo question that an investment project of this size and local importance de-serves to be specifically honoured when taken over into production. Under the patronage of His Highness Sheikh Mohammed Bin Rashid Al Maktoum, Vice President and Prime Minister of the United Arab Emirates and Ruler of Dubai, His Highness Sheikh Saeed bin Mohammed bin Rashid al Maktoum

officially inaugurated Nestlés new factory in the Dubai Techno Park on December 9, 2010.Bosch’s commemorating gift, a pair of ‘golden’ flow wrapper sealing jaws will always remember the project teams of the path gone together to achieve the goals of high equipment reliability, process capability and, as a conse-quence, products with high quality, com-petitive costs and short lead time!


Benjamin Stoll

Phone +41 (0)58 674-7542

[email protected]

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Tailor Made for PerfectionistsSelect ingredients, a passion for perfec-tion and innovative spirit have been part of the corporate philosophy of Chocolat Frey AG for over a hundred years. The highest quality standards ensure that this Swiss company’s products are a real treat, to be enjoyed both at home and abroad. From the procurement of raw materials through to the careful process-ing of the chocolate, each stage in the production process is carried out and monitored by the chocolatiers them-selves. In this respect, it is vital that

detailed preparations are made for seasonal periods of peak production and to minimize standstills caused by defec-tive parts.

In order to help optimize the mainte-nance plans for its packaging machinery, Chocolat Frey uses the E-Portal from Bosch Packaging Services. The E-Portal is an online information and order platform for spare parts available to Bosch customers around the clock. In the case of Chocolat Frey, all the spare parts that are required for its Bosch

machines are listed on the E-Portal. As a result, the ordering of spare parts could not be easier.

Order and Planning Tool To ensure that production cycles during the peak periods of Easter and Christmas run smoothly, Chocolat Frey performs preventative maintenance on its equip-ment. It is essential that the spare parts for the overhaul and maintenance of packaging machinery therefore are avail-able and delivered in good time. The E-Portal allows Chocolat Frey to carefully

The E-Portal Keeps Things SweetIn order to ensure a fully reliable packaging process, Chocolat Frey, the market leading

Swiss chocolate manufacturer, relies on Bosch’s E-Portal for rapid and efficient spare

parts logistics.


plan resources by providing real-time information regarding the availability, delivery time and price of parts. The E-Portal can also be used to assem-ble shopping baskets tailored to Choco-lat Frey’s requirements, which can be used for future maintenance projects. Technical data, together with photo-graphs for identifying the required parts, can be easily accessed on screen.

Despite the Portal containing large volumes of information, it is user-friendly and acts as a live spare parts catalog. Time-consuming searches in paper manu-als and on CDs are thereby eliminated.

New consumption and supply data, based on Chocolat Frey’s inquiries, is automatically added to this spare parts catalog, keeping it constantly up to date.

The system is available around the clock, which means that it can be used as an information and order platform, irrespec-tive of the shift patterns working on site. All members of staff involved in the deci-sion-making process are granted access to information, as required.

Keeping it SweetThe advantages of Bosch’s E-Portal are clear: it is quick, efficient and straight-

forward. It allows a transparent flow of information and rapid decision-making. Chocolat Frey not only benefits from the simplified order process but overhauls can be planned more efficiently, so that it is perfectly prepared when it comes to the important seasons for all things sweet.


Hans Barmettler

Phone: +41 (0)58 674-6679

[email protected]

Mr Schatzmann, responsible for technical operations purchasing at Chocolat Frey: “Thanks to the E-Portal, when ordering spare parts, less insider knowledge is required to carry out the ordering process. Photographs or drawing of parts can be easily compared on screen with the physical parts required, thereby helping to prevent incorrect orders.”

Further information about the E-Portal can be found on our website: www.boschpackagingservices.com.

If you do not have an E-Portal yet, you can request your individual login on this page.

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Automated Biscuit Handling with a Gentle TouchPaterson Arran Improves Efficiency and Reduces Waste with Delta Robotics from Bosch

Paterson Arran, one of Scotland’s best known food companies, has pleased its customers with quality bakery products since 1895, when John Paterson founded his bakery in the Royal Burgh of Rutherglen. From a husband and wife selling home-baked oatcakes to one of Scotland’s best-known and much-loved food companies, Paterson Arran has continued to draw on traditional recipes combined with today’s technology and resources. With over a century of experi-

Besides kilts and bagpipes, Scotland is also known as the home of shortbread and oatcakes – tasty confectionery prod-ucts derived from oat. Since oat is better suited for the wet growing season than wheat, oatmeal has become a key ingre-dient in Scottish culinary traditions and contemporary dishes. Nowadays, many consumers throughout the United Kingdom and other European countries count oat-based products as one of their favorite breakfast and snack treats.

ence, the company is not only known for its shortbread and oatcakes, but also for its giant cookies and range of catering and food service biscuits such as Bronte and Cafe Bronte, mainly supplied to coffee shops, hotel groups and confer-ence venues. Paterson Arran’s success rests on top-notch food made from high-quality ingredients and a continuous stream of innovation.


Flexibility Is All You Need Recently, the company decided to auto-mate one of its existing biscuit packaging lines, which consisted of three flow wrappers that were manually fed. The operators had difficulties picking and placing them accurately into the infeed chain of the wrapping machine at the speed required. An advanced robotic application would be able to efficiently solve this issue, while allowing the relocation of manual operators to other production areas. Additionally, a robotic solution would reduce the amount of product damage and waste.

In evaluating possible technologies, a key consideration was footprint. Paterson Arran needed an automated packaging line that could incorporate its existing flow wrappers without requiring much additional floor space. A high degree of flexibility was required as the line needed to be able to package eight ge-neric products, each manufactured in different flavors, comprising 35 varieties in total. Moreover, the line needed to de-liver different types of pack styles, namely single packs, twin packs and eight packs. The products were to be placed in bags in different orders and

formats, such as stacked, flat side by side, single piece flat or two or three items high. To maintain throughput, a high perfor-mance robot was essential. A picking efficiency of 98.5% was demanded to assure a steady and fast stream of prod-ucts that would be continually fed to the wrappers.

Bosch’s Advanced Automation Is the WayAfter consulting eighteen packaging equipment suppliers, Paterson Arran found the right robotic solutions provider

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in Bosch Packaging Technology. Bosch designed a packaging line encompassing three Delfi feed placers, assembled with two Delta robots each, that would be integrated with a new Pack 201 horizon-tal wrapper from Bosch as well as with two existing wrapping machines. Each Delfi feed placer efficiently feeds one of the flow wrappers.

All three Delfi machines are equipped with a vision system to guide the robot and offer quality analysis while providing coordinates of the products to the robot cell. The Gemini 3.0 software is able to

display 3D graphics of the running robot on a screen, allowing the operator to see if the machine is performing correctly and to adjust any parameter if needed without stopping the line. “The software allows you to see what the robot sees”, said John McBurnie, Operations Director at Paterson Arran.

In addition to the advanced technology, other key drivers of Paterson Arran’s equipment selection were the compre-hensive trials and training sessions of-fered by Bosch at its Swiss facilities and the strong customer service support. Since the successful and fast installation and set up, Paterson Arran was running its new biscuit packaging line at full speed, helping the company meet pro-duction targets.

Hitting the TargetThe new packaging line is able to handle all eight products and their flavor varie-ties, offering the desired flexibility with very short changeover times. McBurnie highlighted: “It is important to say that the line is tool-free to change over, which makes it very easy for the operator.” As reducing waste levels is extremely important in food processing and pack-aging, Bosch has incorporated its newly designed Coanda picking tool. These advanced grippers are not based on vacuum technology but rather on an air-flow principle. In order to be able to hold it, the product is surrounded by air. The Coanda is a non-contact tool and ideal for handling delicate products such as bakery items, offering a significant competitive advantage for food manu-facturers while reducing product damage and waste levels. “A human hand could

never handle the products as gently as this picking tool”, said McBurnie.

The collaboration between the company and Bosch was marked by “complete honesty and openness”, according to McBurnie, who also added: “Both parties had agreed on performance criteria that included four conditions related to mechanical efficiency, picking efficiency and waste and damage levels; all of them were achieved by the Bosch equipment.”

For instance, the OEE (Overall Equip-ment Effectiveness) parameter for the entire line was agreed on and achieved with the new solution, and it resulted in a 5% improvement in efficiency com-pared to the previous manual feeding system. In terms of speed, Bosch’s new robotic solution was able to deliver an output of up to 140 bags per minute. McBurnie stated: “We are very satisfied with the packaging line speed.”

The design of the Delta robots, which is based on parallel axis geometry, is ideal for high speed performance. By enabling fast movements and high speeds, Delta robots correspond with market demands.

Strong Partnership for Great ResultsWith the advanced automated solution from Bosch Packaging Technology, Paterson Arran was able to meet challenging flexibility demands while assuring product quality and reducing waste levels.


Jonathon Titterton

Phone +41 (0)21 644 2530

[email protected]


As Turkey’s largest and most diverse food manufacturer, Ülker has a wealth of experience

in successful capacity expansion. By working alongside its long-term partner, the recently

renamed Bosch Packaging Systems (formerly Sigpack Systems), the company was able

to integrate its latest high-performance packaging line quickly and smoothly.

Ülker’s Expansion Is All Wrapped Up

When looking to install a new line for the primary packaging of its Cokonat and Cikolatali enrobed wafer bars, Ülker needed a reliable, flexible and efficient solution and a supplier they could depend on. A key requirement for Ülker was flexibility – it needed an adaptable line with quick and easy format change

between the two different products. Bosch’s fully automated packaging tech-nologies emerged as the obvious choice to fulfill this role.

A History of TrustOver the course of a twenty-year profes-sional relationship, Bosch has supplied

packaging lines for the majority of Ülker’s bar and biscuit lines. Ülker has come to trust the advice, professional-ism and technical assistance of Bosch’s experts as much as the reliability and speed of its wrapping lines.For the Cokonat and Cikolatali bar lines, Bosch drew on its huge industry experi-

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ence and accumulated knowledge of Ülker’s business to devise a solution that would minimize upheaval and manufac-turing downtime. The proposal for a new packaging line, combining a buffering unit with two high speed flow wrapping machines, was designed with the cus-tomer’s specific needs in mind.

Seamless and SpeedyBosch’s seamless solution creates a steady, uninterrupted flow of wafer bars through the line, from product inspec-tion and distribution through to fast, accurate flow wrapping with cold sealing. The smooth passage of bars through a fully automated line significantly reduces downtime and increases production out-put.

The Bosch technology takes over directly from the cooling belt, after which the

rows of wafer bars are optically in-spected and any misaligned units ejected from the line. After passing through a metal detector, bars arrive at the modu-lar DAA Accumulator – adapted to Ülker’s exact specifications. Adhering to the highest hygiene standards, the products are transported gently by gondolas through the buffer to even out product flow and ensure a constant production stream. Finally, the bars are individually wrapped in pillow packs and sealed using cold sealing at an output of up to 750 bars per machine per minute.

The line can be operated intuitively via touch screens. Parameter entry, fault display, statistics per shift and measures to rectify errors are easily accessed. Easy access allows for rapid changeover when switching to the alternate product. The system is suitable for multi-shift opera-

tion, boosting uptime and Overall Equip-ment Effectiveness (OEE).

A Future of InnovationIn a recent workshop at Ülker, represen-tatives of the entire Bosch Packaging Technology group presented their latest packaging ideas and novelties to Ülker management, technicians and marketing experts and discussed solutions for future developments. Continuing to collaborate, both companies are leading the way to keep bringing Ülker’s most popular products to consumers, not only in Turkey but in many other countries around the world


Hans-Ulrich Hunold,

Phone +41 (0)58 674 6615

[email protected]


Smart and Sustainable Packaging of Mashed Potatoes

Stocki potato mash, by Knorr, is the Swiss version of mashed potatoes and an original Swiss product. It is made entirely with potatoes grown in Switzer-land, is produced exclusively in Switzer-land and has been a Swiss favorite since the early 1960s. The popularity of this Knorr product is such that potato mash is colloquially known as “Stocki”. Unilever, the brand owner of Knorr, has

recently acquired a new packaging line for Stocki folding boxes contained in trays. It was very important to select a highly flexible line with regard to format, as well as the type of packaging used. As Unilever produces multi-layer packages, another key criterion for selecting the new line was a high efficiency factor. Bosch Packaging Technology in Remshalden, near Stuttgart, satisfied

Unilever’s requirements with the selected machine, the Elematic 3000 S, featuring a wealth of state-of-the-art technology. The Management Informa-tion System, for instance, monitors the timing and completion of maintenance operations and remote maintenance allows for analysis and optimization of the line status.

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Smart and Sustainable Packaging of Mashed Potatoes

Packazine interviewed Mr Peter Büeler, Technical Manager, at Unilever, Thayngen, about the selection of the new packaging system:

What were the challenges that led you to seek a new solution for your packaging system? Over the past ten years, we have been able to expand our production volume considerably. The growth in exports was particularly encouraging and now ac-counts for half of our overall volume. This means that we have to produce in line with internationally competitive price levels and require smooth-running equipment. Up until now, we did not have an automated solution for packag-ing folding boxes – and remember Switzer land is a high-cost country – so we looked for ways of increasing effi-ciency. Of particular importance were very high Product Efficiency (PE) and Overall Equipment Effectiveness (OEE).In order to achieve low-cost, efficient and flexible production here in Switzer-land, we require a high degree of auto-mation. Manual packaging operations are increasingly a thing of the past. Based on sales volume, we conducted a profitabil-ity study to calculate payback periods. In the long term, automatic packaging pays off, particularly when one considers that Stocki will still be an integral part of Switzerland’s food industry in ten years’ time. We are also now using recyclable pack-aging material and have stopped using shrink film. The product is packaged in Tray and Hood, whereas previously we used Tray, Hood and Shrink. This eco-friendly production is fully in line with

our corporate philosophy with regards to sustainability. In this respect, Unilever has an ambitious target to halve the envi-ronmental impact of its products, over their entire life cycle, by 2020.

Why did you choose Bosch as a business partner? Thayngen has a long tradition of working with Bosch machine prototypes. We al-ready have two machines, which we de-veloped in cooperation with Bosch Pack-aging Systems. Our factory also has a ro-tary filler from Bosch in Viersen and two tray packers from Bosch in Remshalden. We have always worked closely with Bosch Packaging. Following the decision to acquire the first machine of this type, for packaging soups and sauces for Uni-lever Food Solutions, we were looking for the same machine solution to meet this new challenge.

In your view, what are the advantages of the Bosch equipment?Firstly, we already have engineers who know the machine. Therefore the new in-stallation just requires minimum training, with only the operators needing to be trained. Secondly, it is easier to manage spare parts, which in turn means re-duced storage costs.

We produce 1750 different product units, which is a volume that is unique within Unilever. This means we have to be extremely flexible to be able to serve our customers’ needs. At our location, we can produce seven days a week, 24 hours a day, if required. Of course, this also means that our workforce has to be familiar with a range of machines.

Our customers expect the required quan-tities at agreed times. To be able to meet these requirements, we need a reliable and highly efficient line. This is the only way to plan our production.


Nicole Puschina

Phone +49 (0)7151 7007-97

[email protected]


ing and sealing machine fills baby food into thermoformed cups. The machine allows product-friendly, energy-saving filling operations as part of an automated process. As a result of its high hygiene level, and in conjunction with the upstream process technology, the TFM 8030 PS can deliver product shelf lives of up to twelve months without refrigeration. Products filled with the unit include fruit yogurts and dairy-based des-serts, as well as special baby-food recipes.

Baby Food Production on Bosch Aseptic LineHumana expands productionHumana Milchindustrie is a leading com-pany in the German dairy sector and, for 60 years, has been developing and pro-ducing high-quality baby food. The com-pany places special value on gentle pro-cessing methods and the highest quality standards. In 1950, Humana first intro-duced infant formula to the German market, which was highly similar to breast milk. The product portfolio has developed continuously since then.

Today, the company has 12 manufactur-ing plants, which process a total of two billion kilograms of milk per year to produce a diverse range of dairy prod-ucts. At its Erfurt plant, the company produces baby food, fresh milk, long-life milk and fromage frais, as well as various desserts.

In 2010, Bosch supplied a TFM 8030 PS aseptic thermoforming unit to Humana Milchindustrie. This aseptic forming, fill-

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High output and product safetyThe TFM achieves output levels of 57 000 cups per hour, which amounts to a maximum daily production volume of 100 tons. The plastic cups are formed from reel material, which is much more cost-efficient in the production of baby food compared to prefabricated cups. A barrier of EVOH material is integrated within the film and protects the filled product against oxidation and water vapor diffusion, even over long storage periods and without refrigeration. The multi-layer protective film also prevents mechanical damage to the product. Inte-grated gas flushing of the cup’s head space reduces the residual oxygen con-tent, further increasing product safety.

Maximum filling accuracyAn integrated piston filler ensures highly accurate filling. For viscous products, such as desserts, the filling accuracy for a 4x100 gram pack is approximately ±1 gram. Such high accuracy generates cost savings for the user. With four supply tanks and a direct product feed into the filling nozzles, the piston filler also offers very high flexibility for filling many differ-ent products.

Recipe management is keyThe TFM system allows for the comfort-able management of all Humana’s prod-uct recipes, which number around 100. This includes an automatic transfer of al-terations in technical parameters in case of recipe changes. The control unit com-pletes the automated system. A camera, fitted with automatic image recognition, checks that the correct lid film has been

applied to the product. The control sys-tem then provides the product-specific print parameters for inkjet coding.

Packer delivers high efficiencyFor Humana, high line efficiency is of paramount importance. This is why Bosch has added a packer unit to its sup-ply of machinery. Direct interlocking, and therefore a safe transfer of cups from the cutting station to the packer, and inser-tion in trays are prerequisites for opti-mum line efficiency.

Technical optimizationThe system follows the principle that reli-able and field tested features must be kept but details should be improved. For instance, despite a number of innova-tions, the unit sterilizes the packaging

material for maximum effect using the already proven procedure with H2O2.

Currently, the TFM already offers a range of options and is also highly suitable for processing polypropylene (PP) films, however, executed with different format parts and machine equipment. Bosch is also involved in further technological de-velopment of the TFM and future en-hancements will include a continuous run of lid film in the sterilization pas-sage, swiveling sealing heads for im-proved access and the option of using a cassette for the cutting tool to simplify tool changes.

For further information please contact:

Robert Fesl

Phone +49 (0)711 811 57229

[email protected]

Klaus Birker, Plant Manager at Humana in Erfurt, explains that he and his colleagues had a clear preference for the Bosch concept: “Bosch is a reliable producer of machines. In the aseptic field, we are familiar with these machines and are convinced by their technology. Investment and maintenance costs, a perfect service provision and the line’s high efficiency were the deciding factors for us in awarding this contract to Bosch.”

22 | packazine Events 2011

Events Food 2011

Events Pharma2011

Date Event Location Branch

05.12. – 05.18.2011 Interpack Düsseldorf General

06.07. – 06.10.2011 FOOMA Japan Tokyo Food

06.07. – 06.10.2011 Fispal São Paulo General

06.21. – 06.24.2011 EXPO PACK Mexico Mexico City Food

07.13. – 07.15.2011 Propack China Shanghai General

08.21. – 08.23.2011 China Dairy Industry Show Yinchuan Food

09.01. – 09.03.2011 InProdMash Kiev General

09.09. – 09.11.2011 All Food Tech Bangalore Food

09.22. – 09.25.2011 IPACK Istanbul Istanbul Food

09.26. – 09.28.2011 Pack Expo Las Vegas General

10.05. – 10.06.2011 Pack & Emballage Stockholm Food

10.10. – 10.14.2011 Agroprodmash Moscow Food

10.12. – 10.13.2011 Empack Brussels Food

10.18. – 10.21.2011 JAPAN PACK Tokyo Food

10.25. – 10.27.2011 ProPak Cape Cape Town General

11.08. – 11.11.2011 Andina-Pack Bogotá General

12.02. – 12.05.2011 Pack plus New Delhi General

DateEventLocationBranch

05.12. – 05.18.2011InterpackDüsseldorfGeneral

05.24. – 05.26.2011FCE Pharma Int. São PauloPharma

06.06. – 06.09.2011ISPE Washington DC Conf. VirginiaPharma

06.07. – 06.10.2011FispalSão PauloGeneral

06.21. – 06.23.2011CPHI, P-Mec ChinaShanghaiPharma

06.21. – 06.24.2011EXPO PACK MexikoMexico CityGeneral

06.29. – 07.01.2011INTERPHEX JAPANTokyoPharma

07.13. – 07.15.2011ProPack ChinaShanghaiGeneral

09.01. – 09.03.2011InProdMashKievGeneral

09.26. – 09.28.2011Pack ExpoLas VegasGeneral

10.11. – 10.13.2011TechnoPharmNurembergPharma

10.11. – 10.13.2011Supply Side WestLas VegasPharma

10.18. – 10.20.2011A3P CongressBiarritzPharma

10.23. – 10.27.2011AAPS Annual MeetingWashingtonPharma

10.25. – 10.28.2011China PharmShanghaiPharma

10.25. – 10.27.2011ProPak CapeCape TownGeneral

11.06. – 11.09.2011ISPE Annual MeetingOrlando, FLPharma

11.08. – 11.11.2011Andina-PackBogotáGeneral

11.14. – 11.18.2011ExpoquimaBarcelonaPharma

11.22. – 11.25.2011PharmTechMoscowPharma

11.30. – 12.02.2011CPHI, P-Mec IndiaMumbaiPharma

12.01. – 12.02.2011INTERPHEX Puerto RicoSan JuanPharma

12.02. – 12.05.2011Pack PlusNew DelhiGeneral 11/22-11/25/10

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