Highly flexible Sigpack TTM cartoning machine cuts changeover time from one hour to ten minutes
When a Latin American confectionery company first opened the doors of its factory, little did they know that the organization would become a key player in their business. The initial range of only cookies and crackers has evolved over the years to a diverse assortment of products, including cold cuts, biscuits, chocolates, coffee, ice cream and pasta.
A modern solution for Latin American classics
Among its most popular product ranges are its chocolate and cereal bar brands. To keep up with rising production demands, the manufacturer was looking for a way of upgrading the previously manual secondary packaging process to a faster, automated and more reliable solution.
The cartoner had to be flexible enough to package bars of different shapes and sizes into cartons in packs of 6, 12 and 24 − without causing lengthy downtimes. In addition, a high output would need to be realized within the compact layout of the existing production facilities.
During their search for a suitable technology, the company was drawn to the Sigpack TTM toploading equipment from Bosch Packaging Technology. The TTM’s operator friendly design with fail-proof, fast and fully reproducible changeovers as well as its flexible in-feed possibilities won over the Latin American team.
In close collaboration with Bosch a bespoke interface between the TTM and other upstream packaging equipment was developed. A feeding wheel copes with the high speeds that connected both elements of the line to ensure a smooth and harmonious production flow. The Sigpack TTM’s streamlined design meant installation and start-up was swift. With the launch of the new line, the changeover times for the cereal bar production was reduced from one hour to just ten minutes.
Fast, flexible and under control
At the factory, the new customized interface ensures the flow-wrapped cereal bars are delivered continuously and at even distances to the discharging conveyor of the toploader. Arriving lengthways, the flow wrapped bars are then gently picked up by an FWV feeding wheel, which turns the products 90 degrees before placing them sideways into a PGR grouping unit, ready for cartoning.
Carton erection can be an Achilles heel in automated packaging solutions as it has the potential to slow down productivity. Difficult-to-handle carton materials and formats can decrease production output, result in faulty boxes and jam the production line. The Sigpack TTM is designed to eliminate these issues and achieve a reliable output with its quick-change format parts, fully reproducible format settings and precise carton handling.
With its capacity to package bars of various sizes in four carton sizes using seven different configurations, the Sigpack TTM has been a resounding success. The new topload cartoner has allowed the company to reach a level of flexibility and production output that they were not previously able to achieve with their former manual efforts. The automated process, lightweight format parts and tool-free changeover, mean that they have been able to speed up changes between products from 60 minutes down to just 10 minutes. A single operator is now able to run, changeover and clean the machine.
An instant hit with lasting benefits
For the manufacturer, the new installation has not only boosted production output, it has also significantly improved the reliability and stability of the packaging process. The Sigpack TTM’s highly reliable carton transport features individual carriers for each carton that can be adjusted to fit specific requirements, meaning that each carton is under full control throughout the process. Therefore, the production flow is uninterrupted, reducing downtime and creating a hassle-free production environment. Additionally, packaging and product waste are minimized, and high levels of quality can be ensured throughout the production.
TTM platform: The best technologies combined to exceed
Continuous improvement is central to the TTM platform. Bosch always strives towards new, innovative concepts and a constant increase in efficiency. One example is the new Sigpack PFI. The intelligent high-speed feeding module is adaptive and works without the use of a vacuum. It transports the products very gently at any speed. Thanks to latest linear motor technology, every individual product can be placed in the correct position. Another advantage is its extensive format range. Format changes can be carried out tool-less and quickly or even by the push of a button.
Sigpack TTM portfolio: https://www.boschpackaging.com/en/ttm/toploader/start.html
Sigpack TTM Video: Youtube
Eduardo Dos Santos, Regional Sales Director Latin America
Tel.: +41 58 674 6469
LinkedIn: Eduardo Dos Santos