Bosch's flexible biscuit packaging system passes United Biscuits field test

Bosch Packaging Technology has launched its Two-in-One biscuit packaging system after a successful field test with United Biscuits.

According to the company, it is the first system of its kind capable of pack-style changeovers from slug to pile packs in less than 3 min.

The system’s product handling, horizontal flow wrapping and secondary packaging equipment is designed for gentle and versatile wrapping and case packing of delicate biscuit products. The field test at United Biscuits in Manchester, UK, handled the primary and secondary packaging of the manufacturer’s McVitie’s Jaffa Cakes brand in different formats and sizes.

“During the field test, we were able to take 100% of the McVitie’s Jaffa Cake output through a single machine,” said Simon Breckenfield, strategic capability controller at United Biscuits.

“It has allowed us to take our productivity and flexibility to the next level.”

At United Biscuits, the line packaged McVitie’s Jaffa Cakes in both slug and pile configurations with different cake counts for limited edition flavours. The Two-in-One biscuit packaging system achieves high-speed, fully reproducible changeovers by using the same feeding components for both pile and slug packs, increasing productivity and uptime. The system can handle pile packages with a maximum height of 50 mm, regardless of the number of biscuits.

“We developed the Two-in-One biscuit packaging system as our response to a growing retailer and consumer demand for flexible packaging formats, like smaller on-the-go and larger family packages,” said Daniel Bossel, product manager at Bosch Packaging Technology.

A gentle handling philosophy across the line ensures minimised damage hazards and product contact, while three-dimensional product inspection technology detects broken biscuits and sorts them out. The hygienic design prevents the build-up of crumbs and allows for easy cleaning, facilitating continuous production.

As part of Bosch’s Seamless Systems portfolio, the speeds of all line components are balanced to eliminate bottlenecks and optimise production flow, from distribution to secondary packaging.

“After changing from pile to slug packs, all an operator needs to do is press a button and the machine goes straight away,” said Breckenfield.

The biscuit system is designed for a wide range of case packaging formats for regular (RSC) or half slotted (HSC) cases with retail-ready functionality. The case erecting, robotic loading and optional case closing units are integrated in the case packer, resulting in a reduced footprint.