ROBOTICS


The first one was to increase productivity – to create more product output for a specific number of man-hours. The second challenge consisted of removing the pressure of these additional products on the workforce at the end of the lines, which was very labour-intensive, particularly for the packaging process. “This compelled us to explore new alternatives for the Cremino and Muibon packaging processes,” says Carlos. A decision was made to automate the secondary packaging


operation on one of the two Muibon lines and the Cremino line, using Cama robotic solutions. “These machines enable us to pack our chocolate bars in different formats intended for different channels –wholesalers, supermarkets, and membership-only retail stores. The solution provides the flexibility to achieve all these all these different formats,” says Carlos. During the rollout process for the automated packaging


solutions, there were some hurdles to overcome, as Carlos explains: “It is critical to synchronise the new machines with the existing solutions implemented in the line to thermoform the trays where chocolate bars will be deposited. Furthermore, this process needs to be undertaken with the highest possible speed, to keep pace with four machines that wrap chocolate and feed the Cama Group machines. “Fortunately, we found a solution that ensured everything worked properly.” During the process Nutresa Mexico had the support of two


Cama Group technicians for two weeks, who helped with the implementation and also offered training sessions for the maintenance teams to ensure that they understood the operating principles of the machines. The secondary packaging process now employed is simple.


For Cremino, the Nutresa Mexico teams thermoform the trays, a Cama Group IG270 model unit takes those trays from a feeder and by means of robotic arms, grabs the chocolates transported on belts, and puts pieces on the trays. The IG270 is an automated loading unit that includes two small footprint robots with carbon fibre arms suited to fast product handling applications and an intelligent vision system that allows the robot to sort and pick loose products in a production line and puts them in a container, box, or conveyor in any preset pattern. The Muibon line now employs a Cama Group IF296 unit – a


high-speed monobloc machine that utilises robotic units to assemble, load and wrap boxes and which can also handle wrapped products and flowpack. This unit assemblies the display-box that contains the wafers, loads the wafers inside the box, and then seals it with hot glue.


“The type of robot used, and its design characteristics, needs to be given careful consideration to ensure the highest standards of


cleanliness and food safety are maintained”


The machines offered the company the flexibility it


needed to package a variety of different formats. “It was also important that the equipment complied with all necessary regulations relating to risk, and contamination. We also wanted machines that would ensure operator safety when working with the equipment. Accordingly, both machines are supplied with enhanced security, with stainless parts and safety guards to avoid the risk of entrapment.” There were more positives for Nutresa Mexico. Its global


efficiency, measured with the Global Efficient Equipment, has risen from a global efficiency of the line of 84% to 86%. Furthermore, the installation of the Cama Group machines has resulted in a 14% increase in line productivity. This translates into the production of 300 chocolate bars per minute for Muibon. Since there are two lines, that means 600 units per minute at the Nutresa Mexico plant. The Cremino line is now able to produce 1,080 units per minute. With figures like these it should come as no surprise to hear


that Nutresa Mexico plans to acquire additional robotic machines to continue to automate its chocolate production lines.


When hygiene is key Of course, one of the most important considerations when looking at employing robots in confectionery production applications will be hygiene and, as robots continue to move further upstream into the manufacturing processes,


28 Kennedy’s Confection February 2023


KennedysConfection.com


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