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Customer magazine of Bosch Packaging Technology · Food & Confectionery · Issue 2016

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2 | packazine Table of contents | Editorial

Customer magazine of the Packaging Technology Division,Robert Bosch GmbH

EditorialCentral Marketing & CommunicationsAnnette Soyke (Leitung)Phone +49 711 [email protected]

DesignCentral Marketing & Communications Karin Schmückle

PhotosB.J.Y.L.D (picture editing); Bosch Packaging Technology; Ralf Grömminger Fotografie GmbH; Stock-Asso (Shutterstock)

PublishingBoard of Management Stuttgarter Straße 130 71332 Waiblingen

© Copyright · Packaging Technology Division, Robert Bosch GmbH

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

Customers & Markets

Food & Confectionery

04 Rapunzel | Lucky number three

07 Afición | Taming the dragon with Swiss-like chocolate

10 Wilde Snacks | Wilde Snacks cracks the code

13 DMK | Take a more relaxing tea and coffee break with the DMK cup-fitter

16 TINE | Norway provides dairy products from the vat

18 Brandt | Tradition meets automation

21 UB McVities | Bosch puts the “wow” into packaging McVitie’s Jaffa Cakes

24 Pozuelo | A sweet success: Pozuelo partners with Bosch

26 Mydibel | The tradition of quality

Events

29 Events 2016/2017

Table of contentsImprint packazine

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Editorial

Friedbert KlefenzPresident, Bosch Packaging Technology

Dear readers,

Welcome to the new packazine edition! As usual, we will provide you with a broad overview of stories about our versatile solutions. As of late, Osgood Industries and Kliklok-Woodman from the U.S. and UK, as well as our joint venture with Klenzaids in India, contribute to the expansion of our portfolio on an international level.

This internationality is also reflected in numerous articles. Pozuelo from Costa Rica, for instance, uses Bosch technology to bring its cookies safely from the oven into the packaging. The pan-European food producer Rapunzel Naturkost relies on the comprehensive system competence from Bosch in both primary and secondary packaging.

Complete solutions are also a major decision criterion within the pharmaceutical industry, for instance for our new customer LG Life Sciences from South Korea. We also proved our line competence with a syringe filling system for cytostatics manufacturer Oncotec.

The CPI software that Hikma is using in Jordan and Saudi-Arabia along with 25 CPS modules for serialization shows that we always see the bigger picture. How and where can we further use our cross-divisional competencies for your projects and complete solutions? Read about it in our new brochures, which I am happy to present you together with this packazine. You might be in for a surprise!

Enjoy reading the new packazine.

Friedbert Klefenz

4 | packazine Customers & Markets Food and Confectionery

As one of Europe’s leading manufacturers of certified organic, natural and vegetarian foods, Rapunzel Naturkost is an expert at predicting trends within the organic sector and is already preparing for future market requirements. This kind of approach has allowed the company, which was founded in Augsburg, Germany by Joseph Wilhelm and Jennifer Vermeulen in 1974 as a small natural foods corner shop, to grow into the now global brand – with

approximately 350 employees. The annually increasing revenues in the organic market also affect Rapunzel: the rising demand resulted in business growth and opportunities for expansion at their production site in the Bavarian municipality of Legau, but also presented certain challenges along the way.

Crunchy, creamy qualityThe production lines were no longer able to keep up with

the increasing order volumes and variation driven by ever-changing consumer demands. Therefore, the company was looking for new packaging solutions – from bags to case packing. These lines would ideally be flexible enough to take care of packaging a broad range of products. Ra-punzel’s product portfolio includes chocolate-nut crèmes,

Lucky number threeNatural foods manufacturer Rapunzel and Bosch deliver top quality every day

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cereals and dried fruits, which all require packaging of different sizes and formats. The products filled in glass jars as well as block-bottom and stand-up bags need to be packaged ready for shipping and sale by case packers. Moreover, the new machines should be simple and intui-tive to use, gently packaging the brittle products.

Tried and trusted solutions complete the new line“The foundations for the project were laid when the first order was placed in 2009,” explains Alexander Karst, head of production at Rapunzel. “Bosch stands for quality – and once we got to the stage where the majority of the primary packaging machines in the new lines had been provided by Bosch, we decided to source the case packing solutions from Bosch as well to simplify the operation of the ma-chines for our employees. By opting for Bosch once more, we were able to optimize interfaces and train employees more quickly and effectively. It is also a tremendous help to have one single point of contact for all machine components.” All in all 3 case packers from Bosch are in use at Rapunzel.One of the Elematic 3000 wrap-around case packers pack-ages various glass containers weighing 250, 450, 500 or

750 grams. Up to 50 tons of nut spread and chocolate-nut crème are filled and packed in Legau every day. Bosch installed two further Elematic 3000 wrap-around case packers, which were ready to use as soon as the newly expanded site was reopened. Furthermore, two of the primary packaging machines were also supplied by Bosch: an SVE 3600 WR vertical bagger, which packs cereals, nuts and dried fruits into bags of various sizes using an auger filler, and another Bosch system that fills semolina and breakfast purée into block-bottom and stand-up bags on a PME packaging machine.

A clever planEach of the products – which are manufactured across three lines in total – is now automatically diverted to one of the integrated Elematic case packers. One of the case packers collects and packs glass containers, while the other two place the various types of bags – ranging from 75 grams to 2 kilograms in weight – into cartons of different sizes, all on a single machine. To ensure gentle treatment of all products – especially the fragile glass products, servo drives and plastic machine parts are integrated into the design to provide maximum protection.


This reduces the risk of downtime and minimizes packag-ing and product waste. It is easy to adjust the Elematic to the speed of the respective upstream machine, which increases the efficiency of the production line. In addition, the case packer can be fitted with modules for two-part tray-and-hood packaging and also for full wrap-around packaging. This allows a high degree of flexibility and pro-vides the freedom necessary to satisfy marketing and retail requirements. Thanks to a clear labelling, naming and numbering of machine components as well as structured processes, format changes can be done easily and simply up to two times per day. The Elematic is designed to be easily accessible at its maintenance points.“More and more of our partners and customers want prod-ucts to look good on the shelves as well as being easy to tear open and shelf,” points out Karst. “As such, we knew right from the start of the planning phase that we intend to offer packaging with trays and hoods in future, in addi-tion to the full wrap-around format. This option is already integrated, so we can introduce this pack style at any time. This gives us an enormous advantage when the market re-quires quick adjustments to meet new requirements. While

we were hitting a bit of a wall with our previous systems, the new ones enable us to embrace the kinds of product innovations we previously had no capacities for.”

Well-prepared for the challenges that lie ahead“Here at Rapunzel our philosophy is driven by innovation and forward-thinking – we never stand still. Every day, every week and every task brings its own surprises,” expresses Karst. “With our partner Bosch by our side, and thanks to our new production lines, we are already looking forward to the challenges that lie ahead – because we know that we can handle them with the exact amount of efficiency and quality required.”

For more information please contact:

Bernhard Vaihinger

Phone: +49 7151 7007-67

E-mail: [email protected]

Taming the dragon with Swiss-like chocolateHow the Chinese producer Afición raises a standard of chocolate production with Bosch


As the Chinese proverb goes, if you catch one's heart you will never be apart. This phrase perfectly describes the driving force behind premium Chinese chocolate from Afición. Not only has the company created a high-quality chocolate brand, but it has also established a place where chocolate enthusiasts can witness the process – the museum of chocolate in its Jiashan’s facility, China. Every year it is visited by millions of tourists who come to see how chocolate is transformed from a simple cocoa bean to a perfectly wrapped edible gift. Visitors can also enjoy a gallery of chocolate packaging styles, showcas-ing variations from different regions around the globe. Sapal, a Bosch Packaging Technology company based in Ecublens, Switzerland, has played its part in the creation of this chocolate lovers’ paradise. Its packaging line wraps Afición’s chocolate into perfectly formed envelope-shaped die-folds differentiating the product offering and chal-lenging competitors by raising the standards for product quality, safety and aesthetics.

A sweet dealChina’s economy and society are innovating at a rapid pace – by 2022 its retail market is forecasted to be double that of the United States, reaching an estimated $8 trillion, according to a report by A.T. Kearney1. This is an important message for Western brands in particular, who are close

to the local customers’ hearts. Why? Because Western products have always been associated with high quality and elegance, which means that owning them is a matter of prestige2. This trend is especially visible among the younger generation of Chinese consumers who are willing to pay a premium for high-end products as they become more ‘westernized’ and brand quality-conscious3. Keeping in mind the growing hunger for premium products, the founders of the Afición brand decided that their chocolate will be made to a classic recipe; grinding layer upon layer of cocoa paste resulting in a unique taste and structure. In order to stand out even more at the point-of-sale, it was decided that the chocolate should be packaged in a classic die-fold wrap to reinforce the brand statement. With a long global heritage for providing high quality machinery to the chocolate industry – and over 80 percent of the premium die-fold chocolate packaging market share in China – Bosch was the partner of choice for the Chinese manufacturer. “We required a high-quality packag-ing machine to match our exceptional product, while also preserving the unique taste of Afición chocolate. Not only did Bosch deliver that, they exceeded our expectations,” explains Xue Feng Mo, the founder and general manager of Afición. However, it was not only premium quality of the wrapping and the efficiency of the machine that convinced the customer. “The reliable, fast and local service support provided by Bosch, as well as the additional training for our operators and engineers, goes above and beyond any other machine supplier that we could have dealt with,” adds Xue Feng Mo.

Unwrap the potentialThe result of this cooperation is now on display for the million plus visitors that pass through Afición’s doors. The whole line is 156 meters long and consists of three different parts; the processing unit, where the cocoa mass and sugar is grinded and conched; the tempering unit, where the chocolate is formed into tablets, and finally – the wrapping unit, which features two DSD 0600 die-fold packaging machines and a Transver SDI distribu-

1 Source: http://www.luxurydaily.com/brands-entering-chinese-market-must-appeal-to-unique-preferences/

2 Source: https://www.moduslink.com/chinese-demand-for-foreign-brand-products/

3 Source: http://www.chinabusinessreview.com/understanding-chinese-consumers/

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which gently lead the products across the folding box firstly forming the side folds and then the longitudinal. The product is then transferred to the second revolver, which maintains the pressure after gluing to ensure secure seal-ing. The gripper leads the product, in counter clockwise rotation, to the exit pusher, where it is deposited on the exit belt. With achievable speeds of up to 600 products per minute, stable performance and high line efficiency of up to 7000 tons of chocolate per year, Afición expects to be in a position to export its products beyond the Chinese market very soon. “Before we go ahead with the planned expansion, we will need to think about automating the end of our line. To do so, we will definitely be consulting with Bosch to make sure our goals and business objectives are achieved.”

This is just the beginningWith the help of a single-source solution supplier, such as Bosch, the Afición brand managed to achieve its goal – to create classic Swiss-style chocolate, wrapped in premium packaging, which preserves the unique taste of the product. Additionally, the high level of product protection secures and builds brand loyalty, differentiating it from its competition. With Bosch by his side, Xue Feng Mo achieved a lot more than just satisfying his customers' needs for premium chocolate – he challenged the local market by raising the standards of quality, safety and aesthetics, in turn safeguarding his products against the challenges of tomorrow – today. The successful response to Afición brand from the Chinese audience and sales boosting up to a few thousand tons per year are a strong proof that the journey has just begun.


Michel Tinetto

Phone: +41 21 633 52 33


tion station from Rotzinger AG. In order to ensure product safety each 10 gram chocolate tablet is first checked for any contamination by a metal detector. If approved, the product is then transferred to the two folding revolvers on the infeed belts where it proceeds through separate fold-ing sequences before being hand-packed into gift boxes.To achieve the tidy, classic, die-fold pack style, the choco-lates are separated and covered with packaging material consisting of an inner paper-aluminum layer and an outer paper cover on which the glue has been already applied. They are then picked up by lower and upper grippers


In the world of protein bars, flow wrap is the name of the game. Consumers know and understand this very customary packaging. Wilde Snacks of Boulder, Colorado, wanted to capitalize on this consumer standard, yet give them something they had never tasted before or seen in a typical flow wrap package. When a shopper picks up a Wilde bar they are picking up a meat-based, slow-baked

whole-food savory bar that delivers 10 to 11 grams of protein, but with very low sugar and sodium, all beautifully packaged in a flow wrap. The concept of the young company was seemingly simple – combine premium grass-fed lean meats from animals sustainably raised without growth hormones or antibiotics with fruits, vegetables, ancient grains and spices into a

Wilde Snacks cracks the code and adopts Bosch flow wrapping machinery

Meat-based protein bars use art and technology

to make a statement

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bar. “At the time, there was a lack of anything savory that would deliver high amounts of protein but without all the sugar. The key at Wilde Snacks is that each bar is slow-baked to perfection, allowing the consumer to experience something truly unique,” says Wilde Snack co-founder/CEO Jason Wright.

The Wilde packageThe protein product using GAP (Global Animal Partner-ship) certified lean meats was supposed to be created as a bar rather than having it labeled as “jerky” – a must when Wright set out to create Wilde. “We were tired of the sugary, low protein snack bar options currently available on the shelf. We wanted to give the customer a new savory option but with a recognizable feel, so we chose to flow wrap the bars to give them a familiar package.” Since the consumer would be trying something new when choosing Wilde, Wright and his team wanted to make sure they offered it up in an instantly recognizable package, located on shelves next to the bars they were already accustomed to.“Having the idea is one part, but the execu-tion and developing the innovation is the real work, and the real story,” says Wright, who underlined that the most important thing was to get the right people on the bus from day one. “One of our biggest ac-complishments was convincing JR Crosby to partner with me and Derek Spors to launch Wilde Snacks.”Head of design firm Ptarmak, JR Crosby is the creative force behind the visual brand and design of the Wilde bar. Spors is the brain behind the company’s innovative

formulas and was the creative force behind some of Ben & Jerry’s ice cream flavors. Today, Spors is the owner of Spork and Ladle, a creative lab that offers product development to the food industry. For Wilde, Spors decided to modify the traditional preservation process to see if the meat could be baked at medium temperatures. “We knew that if we were able to crack the code by baking the meat, we could start with premium lean cuts of turkey tenderloins, chicken breast and whole muscle sirloins,” Wright emphasizes. “The problem with traditional processes like smoking is that you must start with fatty cuts of meat, and we didn’t want that,” Wright explains, “and dehydrating would never give us a true bar texture.” After 18 months of research, Derek Spors held in his hands a secret formula that was unique to the product. As the USDA (United States Department of Agriculture) had never seen anything like this before, Wilde then needed to conduct a third party validation study. Wright and Spors hired science professor Dr. Robert Delmore from Colorado State University to validate Wilde’s unique baking process. After three months of testing, Dr. Delmore presented a 15-page validation report to the USDA deeming Wilde’s process to be safe and truly innovative.

The executionWright knows that Bosch Packaging Technology is known as one of the leaders in horizontal flow wrapping so it was an easy choice when decid-


ing on a machine supplier. In addition to the machine, he had to find a film that was strong enough to contain the bar with a seal tight enough to ensure that no air could get inside. Meat packaging must not have any leaks or holes, otherwise the product quality could be compromised. “With Bosch we felt comfortable to achieve hermetic seals, which was one of the main reasons to partner with Bosch,” Wright says. In order to verify the requirements, Bosch performed tests at their plant prior to ordering the equipment and demonstrated their capability to seal the packs at the required quality and speed. Wilde Snacks decided to go with the Pack 101 horizontal flow wrapper, which is an entry-level solution that offers a wide format range. The machine is capable of packaging up to 150 bars per minute and comes with an all-servo motor design that enables quick and easy recipe changeovers with a push of a button. It also optimizes film usage and reduces product waste during production, while offering low operating and maintenance costs. This is accomplished via functions such as no-product-no-paper, elimi-nating film waste as well as no-gap-no-seal, eliminating downtime due to a contamination of the sealing jaws. Multiple cutting head sizes are available which allow for flexible machine configuration and a wide range of product sizes. “We love the consistency of the machine. It produces the perfect seal we need every time,” says Wright. The demand for quality

meat snacks has grown in double digits for the last five years1. “The wave is coming,” Wright says, “and we’re out there with our surfboard.”

1 https://www.mclaneco.com/content/sms/en/resources/articles/snacks-meat.html


Jana Ujevic

Phone: +1 715 243 2503


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Take a more relaxing tea and coffee break with the DMK cup-fitter

Latest solution from Bosch Packaging Technology provides

innovative packaging design for Deutsches Milchkontor


We’ve all been made familiar with the drawbacks of the little round milk portion packs at some point during our lives; whether in the canteen, the conference room, or on airplanes. They fall over easily, often straight off the sau-cer, and have a tendency to squirt in every direction upon opening. It was these flaws that were the driving force behind the DMK GROUP’s decision to create and develop an innovative packaging design that has been successfully implemented – in collaboration with Bosch Packaging Technology. DMK Deutsches Milchkontor GmbH is Germany’s largest dairy company, which was founded in 2011 as a result of the merger between Humana and Nordmilch and now be-longs to the DMK GROUP. It is supported by over 8900 active milk producers and around 7400 employees. Today, DMK processes 6.8 billion kilogram of milk at 17 dairy lo-cations throughout Germany. Another eight locations manufacture baby food, ice cream and health products, such as nutritional supplements and glucose products. Brands, including MILRAM, Ravensberger, Osterland, Old-enburger, Humana, intact, Leben’s, Biolabor, hansal and NORMI, mean that the DMK GROUP is a clear favorite for retailers and consumers in over 100 countries worldwide. In 2014, the company generated a turnover of 5.3 billion euros, making it one of the leading dairy companies in Europe.

New design for greater convenienceThe cup-fitter, which the company has developed for the MILRAM and Oldenburger brands has been described as

an exceptional packaging innovation for coffee cream and condensed milk. The innovative packaging design is char-acterized by its teardrop curve shape that fits perfectly against the side of a coffee cup. Furthermore, the new shape ensures spill-free opening and non-drip pouring – perfect for a relaxed cup of tea or coffee. Advantages of the popular and practical coffee creamer portions are their extended shelf-life and easy storage as well as indi-vidual dosing. They also decrease wastage by removing the need to open a larger container.

Successful collaboration with Bosch“The usual round shape is well-known, but the teardrop de-sign is something new. Not just for consumers, but also for us as manufacturers,” reports Sönke Ingwersen, production manager at the dairy company since 1980. It was, therefore, important that the DMK GROUP had an experienced part-ner by its side throughout the entirety of the project. With more than three decades of successful collaboration experi-ence, DMK once again selected packaging specialist Bosch Packaging Technology to help turn this ambitious project into reality. “No disadvantages of the new packaging design in regards to sustainability or costs should appear,” explains Sönke Ingwersen. After DMK had approached Bosch with a sketch of the initial design and strict guidelines regarding material consumption, the machine manufacturer tested the project on its own machines. Finally, the thermoforming machine TFA 2520 whose forming tool can be individually adapted to the requirements of the cup-fitter, was selected.

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The forming tool of the thermoforming machine TFA 2520 can be individually adapted to the customer’s requirements.

“We selected the TFA 2520 because no corresponding competitor on the market of thermoforming machines was able to match our requirements. It’s in this area that Bosch really has a unique selling point. It was a simple choice to work with Bosch due to the many years of good experience that we’ve had with both their machines and services,” summarizes Ingwersen.

Sterile packaging thanks to special aseptic technologyThe thermoforming machine in use was developed by Bosch to package liquid and viscous products, such as coffee creamers, aseptically in thermoformed cups. The special aseptic technology ensures a long shelf-life for foods without any need for cost-intensive post-steriliza-tion, cooling or the addition of preservatives. Highly pre-cise filling devices, reduced material consumption and low maintenance costs ensure an economic production. In addition, the robust machine construction guarantees a reliable production and a long operating life.“The quality of the machine was very important to us. If we have a non-sterile cup in every box and receive com-plaints, it has a very negative effect on our business. Therefore, safety is our first priority,” says Ingwersen.

“The foil we now use is practically germ-free, thanks to the applied sterilization process. Out of 100 000 product cups, we know that there won’t be a single one that isn’t sterile.”

Rapid implementation and optimal resultThe cup-fitter was a complete success! Following the indi-vidualized production of the complex machine, which took around one year, the operational start-up was carried out without any complications. Production was able to begin just four weeks after delivery. Daniela Dethmann, Senior PR Consultant for Consumer Communications at DMK GROUP adds satisfied, “The dispenser is now offered on passenger flights. Even in this testing environment, the new packaging holds up to the pressure. Furthermore, we’ve had a really good reaction to the new shape. Con-sumers are satisfied, which means we’re satisfied.”


Robert Fesl

Phone: +49 711 811-57229



Norway provides dairy products from the vat

Innovative solution from Bosch subsidiary Ampack increases

productivity and flexibility for TINE SA

In the past, dairy products were produced on farms in dif-ferent types of wooden containers, mainly vats. In later years, products such as butter and cheese were also stored in these vats to keep them fresh. In the far north of Europe, in Norway, such a vat carved from wood is called a “tine” and is being used in the dairy industry even to this day. TINE SA, with headquarters in Oslo and a total of 5675 employees, has adopted and trademarked the “tine” as its company logo.TINE SA, in operation for 133 years, is Norway’s biggest producer of dairy products. Established as a cooperative of 15 000 Norwegian milk farmers who are as members al-so shareholders, TINE SA processes 1.4 billion liters of cow’s milk and around 19 million liters of goat’s milk every year to produce premium dairy products. Strict controls and state-of-the-art technology are fundamental for the company to guarantee the highest quality. The portfolio encompasses around 200 different products, such as yoghurt, sour cream, and various types of cheese, which are sold – also worldwide – under the TINE brand.

Set for the future“We had taken over the production of another dairy facto-ry, which had closed, and needed to ensure that we achieved higher production volumes,” says Havard Lam-berg, process engineer at TINE SA. “In addition we also wanted to improve hygienic standards across the whole production process. We had already filled non-preserved dairy products and also wanted to ensure the best possi-ble cup sealing during the packaging process. The new cup filling machine should also be easily integrable into the existing packaging line. The very narrow timeframe posed a significant challenge for us.” In order to implement this ambitious plan, TINE SA was looking for a reliable partner. In 1999, TINE SA acquired a machine from the packaging specialist Ampack, followed by three further machines as a result of successful cooper-ation. The company, with its headquarters in Königsbrunn near Augsburg has been part of Bosch Packaging Technol-ogy since 2012 and develops, produces, and sells filling and sealing machines for liquid and paste-like food prod-ucts worldwide.

packazine | 17

The packaging specialist designed a customized cup filling machine: formed of eight inline lanes and equipped with cup placing, sterilizer, dosing device, lid station, sealing station, snap-on lid station, packer, and tray transport for filling pre-formed cups with various products, such as yo-ghurt products, viscous dessert products, sour cream and cottage cheese. With these different components, the sys-tem is ideally suited to implement the company’s extensive product range. “For us at TINE SA, product quality is of utmost impor-tance,” says Havard Lamberg. “With the new Ampack pack-aging line the quality has improved further. The customers therefore get exactly what they expect from us. Also the system’s hygienic design has demonstrated to us that the construction has been well thought-out, resulting in an optimized cleaning process with minimal effort.”

The right choice When purchasing a new machine, the ability to combine maximum productivity with a high level of flexibility was vital for TINE SA. The new packaging line is designed to handle 18 000 cups per hour (a 50 percent increase in comparison to the previous model) and several different cup formats as well as different packaging materials on the same machine. Despite TINE SA seeing an increase in its production margins, the effort required by the operating

personnel remains about the same and the compartment only has to be re-filled every 12 to 18 minutes. “Since the layout of the new machine replicates the previous one and also control and operation remain pretty much unchanged, our employees were therefore able to work with the new Ampack technology without any problems,” explains Havard Lamberg. The high-performance system runs a two-shift operation for five days a week, with machine stop-pages kept to a minimum, resulting in very little downtime. As a result, TINE SA was able to increase production in line with its objectives – and without significant production losses during the installation phase. Also commissioning the inline machine was trouble-free, allowing efficient pro-duction to start after only two weeks. In the end, the project was a resounding success for TINE SA. The Ampack solution impressed with its innovative technology and outstanding service. Havard Lamberg emphasizes, “The positive partnership has accelerated the whole process significantly. We are delighted with the assistance and service, and that we could rely on profes-sional support throughout the project, from start to finish.”


Eberhard Meinikheim

Phone: +49 8231 6005-41



Tradition meets automationBrandt is using flexible robotic technology from Bosch

to package its famous rusks

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The crispy, crunchy rusk brings back childhood memories and puts a smile on customers’ faces, both young and old. For over a hundred years, Brandt rusks have been a famil-iar playground companion and a great way to start the day at breakfast. Known across Europe for its famous rusks, the family-run business employs more than 800 employees. Approxi-mately 17 000 tons of rusks are produced each year and are mainly sold in Europe, but even shipped as far afield as Japan. The headquarters is located in Hagen, Germany. The company owes its success to the long-lasting trust it enjoys among its customers and its innovative approach to product development.One such development, which is currently very popular with consumers, but initially challenging from a packaging perspective, is the flavour coatings applied to some rusk types. The freshly baked rusk slices are randomly placed on the conveyor belt during production. To pack the slices into paper trays, the company was looking for a highly ver-

satile pick and place technology. The products needed to be oriented and positioned with accuracy and in straight lines, with quality checks to ensure that only products meeting the quality standards were packaged. Moreover, gentle handling was essential, particularly for rusks with irregular surfaces or a premium chocolate coating.The company was therefore looking for a solution that could both increase production and increase flexibility. Brandt analyzed various solutions before opting for a Delfi feed placer, which features an integrated vision sys-tem and three high-performance Delta robots from Bosch Packaging Technology SA.

Expertise to get excited about“It was Bosch's expertise that won us over. The offer they put together was exceptionally detailed. We were confi-dent that Bosch had asked the right questions, really ad-dressed our product needs and come up with the most suitable solution for us,” explains Marco Geimer, plant manager of the Brandt plant in Ohrdruf, Germany, the man behind the decision to buy the machine. The Delfi solution was a success from the very beginning as the rusk manufacturer was able to boost its output signifi-cantly. This increase can be attributed to both, a higher pick and place speed and lower rejection rate which results from a gentler product handling. Two end effectors per robot pick the rusk slices and place them into the infeed chain of the downstream tray loader. This involves a rather unique application. The products are lifted up very carefully by Venturi based end effectors. This approach ensures that the robots’ air tubes are protected from contamination with product particles, which reduces cleaning and mainte-nance efforts and, as a result, avoids downtime.Geimer is convinced, “We haven’t taken things as far as we can yet. The machine is designed to handle 390 products per minute. We are looking to achieve this quantity by opti-mizing the entire production process step by step.”


Flexible and reliable technology that really deliversIt was important for Brandt to reliably package the various rusk types with different properties on a single line. Cur-rently, the Delfi system is handling four different flavours, including rusks with a chocolate or coconut coating.Plans for continuous product expansion will prove no problem for the Delfi feed placer. The integrated and cam-era-based vision system ensures precise picking and plac-ing by recording all products before they are being picked up by the robots. Via parameter settings of the vision sys-tem, new product formats can be added and easily simu-lated on the human machine interface (HMI). This can be executed without using actual products and during pro-duction.New product types also present the company with novel challenges from a quality assurance perspective. The Delfi feed placer has excelled in this area as well. The vision sys-tem performs continuous quality inspections by detecting defective products on the basis of predefined specifica-

tions. These are not picked up, which means they can then be rejected automatically. This critical task has previously been done by hand. “But no employee can oversee a con-veyor belt filled with products and guarantee full quality,” says Geimer. “With the Delfi system, we now enjoy almost a 100 percent control.”

New pick and place system strengthens partnershipThe partnership between Brandt and Bosch Packaging Technology SA dates back more than 18 years. 14 Bosch solutions have already been integrated into the rusk manu-facturer’s production processes which was a big advan-tage for incorporating the new system and integrating the various interfaces. The long-standing collaboration has proven valuable in terms of ensuring the Delfi solution was perfectly adapted to meet current as well as future pro-duction needs.“Product handling is now more hygienic and efficient than ever. The Delfi picker is working so perfectly that we’re even receiving feedback from employees when the produc-tion process on other machines isn’t working quite so well. This information helps to identify needed improvements on the production side. All in all, the collaboration has been an enjoyable experience and has led us to consider further joint projects with Bosch.”


Marc de Vries

Phone: +41 21 633 52 00


With some of the best-loved brands in the industry, the 1948 founded snack food pioneer United Biscuits is synon-ymous with biscuit manufacturing. One of United Biscuits’ flagship products is the tangy and soft McVitie’s Jaffa Cakes. Launched nearly 90 years ago, Jaffa Cakes quickly became established as one of the most popular brands and, after being officially classified as a cake in 1991, were ranked the best-selling ‘cake or biscuit’ in the UK in 2012. It is clear that when United Biscuits was looking to test

new packaging technology for this flagship product, expec-tations were high. With retailers and consumers increas-ingly demanding flexible, smaller and unique pack styles and formats, legacy production facilities were struggling to keep up with changing market needs. Producing standard McVitie’s Jaffa Cakes in both slug and pile configurations in packages of twelve or other format counts of limited edition flavors required regular and fast changeovers. The new solution had to deliver speedy format changes, keep

“Happy, easy, wow”… how the Two-in-One

biscuit system made United Biscuits’ operators

smile

Bosch puts the “wow” into packaging McVitie’s Jaffa Cakes


downtime at a minimum and maximize the existing layout space. Moreover, the tech-nology would have to satisfy United Bis-cuits’ strict requirements with regards to gentle handling to ensure optimum product quality. A first in flexibilityWhile evaluating different solutions to find the right match for the challenge, United Biscuits was captivated by Bosch’s Two-in-One biscuit packaging system with fast pack style changeovers from slug to pile packs in less than three minutes. Its ultimate packaging flexibility coupled with the long partnership between both compa-nies, meant that the manufacturer did not hesitate to ap-proach Bosch Packaging Technology to see if the technolo-gy could be tested in the industrial environment of its Manchester facility.

Gentle, fast and versatileWorking actively with United Biscuits, Bosch quickly real-ized that to implement the Two-in-One biscuit system in the McVitie’s production process also required a new way of feeding products into the machine. Also, the field test runs needed to be integrated into the ongoing production without interruption – which meant a dual role for the feeder system. As a result, a feeder was developed, which could serve the existing packaging line, but also be linked up with the Two-in-One System. “In the initial stages of the field test, we assessed the ability to package multiple product piles as well as slug packages,” says Simon Breckenfield, strategic capability controller at United Biscuits. “We found that the very fast changeovers actually could be translated into the industrial environment.”Instrumental to the system’s speed and flexibility is the

customized state-of-the-art feeding technology that trans-ports the Jaffa Cakes into the horizontal flow wrapper. The system uses the same feeding components for fully re-producible changeovers without the need to change parts, allowing for different pack styles, shapes, sizes and counts to be packaged on the same line. It is the only one of its kind capable of changing the pack pile configurations in record time – no matter if 1, 2, 3, 4, 5 or more biscuits are required, pile packs with a maximum height of 50 millime-ters (about two inches) are possible. The line is part of Bosch’s Seamless Systems’ portfolio of packaging solu-tions designed to eliminate bottlenecks, minimize down-time and optimize production flow. The most common form of McVitie’s Jaffa Cakes are round, 54 millimeters in diameter and have three layers: a Genoise sponge biscuit, a layer of orange flavored jelly and a coating of chocolate. Of course, with a product as sensi-tive as this, gentle handling was another key criterion on the list of priorities. Breckenfield explains, “One of the things that really attracted us to the Two-in-One biscuit

packazine | 23

system was that our philosophy of gentle product handling that minimizes product damage was carried through in the technology. The product is handled on the flat, with very little contact right up until the point where the stack is built into the final packaging format. We believe this will offer a significant improvement in terms of product quality as it allows you to handle even difficult and fragile prod-ucts safely and gently.”

Happy. Easy. Wow.As the field test drew to a close, Breckenfield expressed confidence about the impact the system could have on United Biscuits’ business, “It has been a very successful project which has allowed us to take our productivity and flexibility to the next level. It delivered the route-to-market solution our commercial team has been pushing for. We believe, with the Two-in-One biscuit system, we have a sys-tem capable of packaging almost any biscuit imaginable and a solution for many of the problems facing us in our business going forward.

In short, we can sum up Bosch’s system in three words: 1. Happy: the people who work on it – engineers, opera-

tors – love it. 2. Easy: even when taking in 100 percent of the through-

put of product range, the system does not seem to be sweating or straining.

3. Wow: because having been with the business for 36 years, I have never seen a machine that is capable of what Bosch’s system can do with such panache.”

Currently, 2.9 million Jaffa Cakes are produced in the UK every day – and their popularity is as high as ever. With the Two-in-One biscuit system, United Biscuits has laid the foundations for a modernized, flexible and efficient envi-ronment, for a competitive and happy future.


Daniel Bossel

Phone: +41 58 674 73 11



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To Pack 201 HShorizontal flow wrapper

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The first thing that comes to mind when we think about the Republic of Costa Rica are either the beautiful beaches, or its natural rainforests and exotic wildlife. However, this country in Central America offers so much more than just a perfect holiday destination. It is, for example, the headquarter of the leading cookie producer in the region – Pozuelo Cookie Company, a subsidiary of Nutresa Group S.A., that delivers an array of sweets and confectionery to the regional markets. Pozuelo reinforces the Group’s core strength of longstand-ing experience in the Central American market – with its nearly 100 years of expertise – by focusing on creating the best products possible for its sweet-toothed consumers. However, the rapidly growing market along with difficult climate conditions have required the company to enhance its packaging line while increasing productivity to maintain its strong position in the market. In order to achieve this, Pozuelo turned to Bosch Packaging Technology for an all-in-one packaging solution.

The path to successThe quest for increasing productivity started in 2013, when Pozuelo began searching for new solutions within a limited budget that would improve the output of its “Chiky” biscuits line. Although extremely popular among consumers in the region, the snack posed a unique packaging challenge, due to the bottom half of it being coated in chocolate. Costa Rica’s hot and humid climate presents a risk to the biscuit’s chocolate layer. In order to ensure the customer would experience only the best version of the product, the cookies had to be packaged

in a systematic way that allows the chocolate side of the cookies to not face the packaging film.Allowing the biscuits the proper time to cool down after baking and prior enrobing was also an issue – not only because of the high temperatures in Pozuelo’s facility but also because of the tight factory footprint. These factors drove Pozuelo to seek an all-in-one solution provider that could work with the company to deliver a custom line suited to its individual requirements.Pozuelo also had a limited timeframe to research and select a supplier because of increasing market demands. Fortunately, the company was familiar with Bosch Packaging Technology because its sister brand had also worked with the supplier in Colombia. After witnessing this successful partnership, the cookie producer turned to Bosch for a solution, relying on the company’s reputation for supplying high-quality system solutions. “Money is key in this region, and as a leading cookie manufacturer, we wanted the best technology for the best price. That’s why we were looking for a supplier that could meet our integration needs and offer all of the technolo-gies on our list. Being familiar with Bosch’s work, we were confident of a successful outcome,” says Santiago Builes Maya, director of operations at Pozuelo.

Costa Rican based company increases its

capacity by 25 percent with new integrated line

A sweet success: Pozuelo Cookie Company partners with Bosch

packazine | 25

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Harmonious integrationFrom the start, integration of the equipment was a key goal for the cookie manufacturer and Bosch was able to provide a custom-fit solution that matched both the cookie manufacturer’s budget and needs. The new line for the “Chiky” cookies included a Rotzinger belt conveyor system, a CKG 1300 cooling tunnel and two Pack 201 HS horizontal flow wrappers. In addition to providing these technologies, one important piece in the decision making process was the human factor: Bosch has a strong reputa-tion for its consulting expertise. Having Nelson Morera, sales representative in Costa Rica, and Carlo Medina, regional sales manager for Central America and Caribbean Island, hands-on throughout the integration process along with product specialists from Bosch, ensured the solution was the perfect fit for Pozuelo. “Both became familiar with our needs and truly under-stood them. They provided consultation and guidance to our team throughout the decision process, enabling us to

have the new system solution’s details outlined and articu-lated in a way that made logical sense and was beneficial,” Builes notes.

Sweet smell of successBosch worked closely with Pozuelo to ensure that the en-tire system solution was installed and integrated smoothly. A few years into production, Pozuelo has been running the new line with higher productivity than ever before. “We’ve seen quality results on our existing line and also increased our capacity by 25 percent. Today we run our line with more productivity than ever before and look forward to future cooperation with Bosch.” comments Builes.


Jana Ujevic

Phone: +1 715 243 2503



The tradition of qualityBelgian family business Mydibel relies on Bosch to meet

the latest hygienic design standards

packazine | 27

In family businesses, trust and reliability are at the root of everything. Since many of these businesses are small or mid-sized, it is vital that all processes and procedures run at peak efficiency and that unique selling points are fos-tered to stay competitive with global players that have ac-cess to a wider range of resources. Belgium-based Mydibel is an excellent example of such a company. The son of farmers, Roger Mylle, has had a passion for agriculture since early childhood and his dream has always been to establish his own company. This dream came true in 1988 when he founded Mydibel, a producer of a wide range of chilled, frozen and dehydrated potato products. Today, his two sons, Bruno and Carlo, are running the company pro-cessing an astonishing 150 million bags (that’s 225 000 tons!) of finished potato products per year, marketed under its own name as well as private label brands. The latter comprise more than 50 percent of the company’s business today. To thrive in a highly competitive commodity market, Mydi-bel is always seeking ways to stand out from the crowd. A core mission has always been consistently delivering the highest quality – a fact that has won the hearts of consum-ers in over 120 countries. The company also has a strong commitment to environmental protection and maintains stringent green factory policies. Mydibel has recently in-vested in a new fully automated potato sorting process that reduces water consumption by 50 percent and a new fermenter that allows for 100 percent green electrical and for 25 percent thermal energy provision. With an increased emphasis on food safety demanded by today’s consumers, customers and international authori-ties, Mydibel makes it a priority to keep up with the latest hygienic design standards and requirements. Partnering with Bosch Packaging Technology, its long-standing part-ner, Mydibel found the optimal packaging solution to en-sure the highest possible product quality and a hygienic environment to meet the hygiene standards of today and tomorrow.

Only the best is good enoughMydibel chose Bosch’s vertical form, fill and seal machine SVC 4020 to package its potato products in 500 grams to 2.5 kilogram pillow bags at a speed of up to 70 bags per

minute. The continuous motion solution was designed to prevent contamination and simplify cleaning. It also helped Mydibel to meet high hygiene requirements and achieve ef-ficient production. “Quality is the essence of the Mydibel philosophy and we expect the same from our suppliers,” says Carlo Mylle, CEO of the Mydibel Group. “The SVC bagger from Bosch meets our needs perfectly. Thanks to its easy-to-clean design, high-quality bags, and flexible set-up, the new technology helps us keep our customers happy and loyal.” The features of the SVC 4020 make it ideal for supporting hygienic packaging environments, while its design allows for the highest hygiene levels. To prevent contamination, logos and rulers are engraved for easy and thorough clean-ing. In addition, tilted surfaces and rounded corners will not trap potato residues, significantly reducing the possi-bility of any bacterial build-up and ensuring the consis-tently high quality of Mydibel products.“Hygiene and time are vital assets to our customers,” com-ments Patrick Lagarde, engineering and design manager at Bosch Packaging Technology. “As a result, we specifically developed the SVC 4020 to offer a speedy, efficient clean-ing process and reduce production downtime.”


Mydibel’s rigorous attention to delivering first-class prod-ucts has helped the business grow exponentially. With the SVC 4020 the company is well positioned to keep up with increased production demands. “The SVC 4020 is 20 to 25 percent faster than the previous generation of vertical baggers and technologically more advanced,” adds Mylle. “It reduces product waste and downtime.” Mydibel operators benefit from the open-frame design of the new bagger and the user-friendly Human Machine Interface (HMI), which further contributes to time savings on maintenance, cleaning and running. For example, the SVC’s splicing table is ergonomically designed to slope at 45 degrees to allow easy access and film reel replacement, while the intuitive HMI minimizes staff training time and provides clear data read-outs and offline monitoring.

The world of potatoes After more than 27 years in business, Carlo Mylle is savvy enough to know that to be successful, products must also have an appealing presentation on the shelf to attract con-sumer attention. As a result, the company has continued to invest in packaging that supports the brand’s mission

and image. “The first thing our customers see is the bag, so it has to look perfect,” explained Mylle. “In this respect, Bosch quality and the SVC 4020 is a perfect match for our brand.”The SVC 4020’s flexibility and ease of changeover are also key benefits for Mydibel. It allows operators to quickly switch between different potato products and accommo-dates both laminate and polyethylene foil. To further enhance operational efficiency, product and bag change-overs are quick and require no tools.

Power of trustWorking with a partner that shares the same values and principles is a foundation of success for Mydibel. For the past 25 years, Bosch has supplied a number of vertical packaging machines to Mydibel’s three production sites. For Carlo Mylle, this long-term relationship is based on trust. That is why, in contrast to the usual practice of re-placing one machine at a time, Mydibel ordered seven SVC 4020s at once. This allowed the company to boost produc-tion by 30 percent, while ensuring consistent quality. “With Bosch we have found a reliable partner that antici-pates our needs with technological advancements, allow-

ing us to stay ahead of the competition,” he com-ments. “We look forward to continuing our work together as we continue to grow in the potato market.” For more information please contact:

Robert van Mol

Phone +31 495 574 027


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