HIGH-SPEED PRODUCTION


can give operators targeted support for troubleshooting, even when the cause and the fault appear at different points in the process. The FPC6, for example, recognises when faults at the discharge section are caused by upstream process steps such as product synchronisation. In such cases, the control system specifically indicates possible root causes, reducing downtime and avoiding unnecessary interventions. Overall, to ensure speed and product handling are properly balanced in the packaging hall, it is important to combine continuous, synchronised motion with flexible machine concepts, intelligent operator guidance,


reproducible


format changes and error-prevention technologies.


Maximising OEE Matthias Drees, President at OKA, also highlighted the challenges of high-speed production when working with fragile and delicate products. “Confectionery items, such as hollow chocolate figures, aerated jellies, marshmallows, or brittle wafers, are extremely sensitive to acceleration forces, impact, and temperature fluctuations, so the challenge lies in maximising Overall Equipment Effectiveness (OEE) without driving up waste and reject rates due to product damage,” he said. To maintain the delicate balance


between maximum line speed and gentle handling, confectionery manufacturers are increasingly relying on advanced automation technologies in the packaging zone. At the same time, they are encountering upstream process parameters within the forming equipment that can present a new bottleneck. Matthias believes that replacing traditional conveyor belts with linear-motor-


driven shuttle systems can offer a solution. “With this technology, acceleration and deceleration curves can be mathematically tailored to the exact fragility of the product, virtually eliminating jerky movements during transitions,” he said. “Similarly, in pick-and-place applications, high-speed Delta robots are now being paired with advanced sensor technology. The implementation of soft grippers – engineered from flexible, food-safe silicone – or vacuum cups with integrated pressure regulators can effectively prevent surface marks, bruising, or cracking. Concurrently, high-speed 3D vision systems detect the exact orientation and geometry of the product within milliseconds, ensuring the robot calculates the optimal grip point without risk of collision.”


Meanwhile, back in the processing


zone, throughput is still heavily governed by the physical process parameters. “A prime example of this is the highly aerated Angel Kiss, a product characterised by its exceptionally low density. Such delicate composition requires unique, dedicated forming equipment. “Innovation has brought us to the edge of physics. Today, the limit of high-speed processing and packaging is no longer the capability of our machines, but the integrity of the product itself,” continued Matthias. “While we have consistently pushed technological boundaries, pushing the process beyond a certain speed will cause such delicate masses to simply collapse.” This reality underscores the fact that higher packaging speeds remain fundamentally dependent on the stability of the upstream forming process and highlights the importance of considering total-line solutions – an approach that looks at the entire process from raw material handling through to final packaging. In this way high throughput and delicate handling are no longer mutually exclusive. “By strategically deploying targeted automation and respecting processing limits, it is possible to boost throughput while simultaneously reducing product waste – a crucial step to securing both premium product quality and long-term competitiveness,” concluded Matthias. “Although machinery engineering always aims to increase speeds and line efficiency, we are ultimately bound by the laws of physics governing raw materials and processing and the raw material’s physical matrix may still be the limiting factor when it comes to speed up process lines.”


JUNE 2026 • KENNEDY’S CONFECTION • 25


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