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design avoids product breakage and loss which enhances not only product quality, but also the overall line efficiency. In addition, the simple design makes the system particularly flexible as it allows manufacturers to process products of varying shapes and sizes – operators can easily perform format changes at the push of a button. Adjusting the belt’s processing speed is just as easy: Once the right command is entered on the integrated HMI, the belts change their speed accordingly. The faster its belts move, the more cookies are distributed onto individual packaging legs. On the legs, an additional belt slide arranges the straight product stream into an S-shape. This ensures that the cookies and crackers are evenly distributed across the entire width of the belt, preventing them from wedging or overlapping and breaking.
Handling fluctuating output automatically In case more cookies or biscuits leave the oven than a singular DCS can handle, multiple stations work together to process the product surplus – and they do so without the operator’s help. The system automatically increases discharge capacity of individual stations and discharges fewer products onto the overloaded packaging leg. At the same time, it distributes the product surplus to the following stations. All legs can continue to operate continuously, until the product storage is empty, and the product build-up has been safely processed. The automatic feature counteracts product loss by minimising the number of cookies on each packaging leg, reducing the probability of breakage and minimising food waste.
Robots handle with care Once the cookies have been distributed successfully, it is often pick-and-place robots that perform the following processing step. If the products have not yet entered the packaging leg, the robots pick the cookies individually from the transportation belt and place them into the infeed of flow wrappers. Alternatively, they can pick the products from the transportation belt of the packaging leg and place them directly into trays. Additionally, they load pre-wrapped products into cartons for secondary packaging. Specifically developed End-of-Arm (EoA) tools are the key to their versatility: By switching out the EoA tool, operators can ensure their automated helpers are able to process different products and formats in varying sizes and shapes.
Linear motors ensure smooth and gentle movement Whether it’s robotic solution or conveyor systems, that manufacturers opt for, both technologies rely on integrated linear motor technology to ensure smooth movements. The motor’s smooth and slow movements reduce mechanical stress on the cookies and prevent breakage and product loss. Linear motors can be operated individually, ensuring highly precise handling processes. Integrated into infeed modules for flow wrappers, for example, they perform exact portioning and increase the packaging lines’ output when combined with smart acceleration: Once an individual infeed mover takes hold of a cookie or a grouped cookie stack such as a slug pack, it accelerates automatically and transports the products into the wrapper. Often, there is no one-size-fits-all solution. In most cases, manufacturers opt for an application- and product-specific
bakeryproduction.co.uk
Machines offering quick format changes and compatibility with different pack styles allow manufacturers to produce a variety of baked goods
Belt slides of discharge stations ensure that bicuits or cookies smoothly slide over the belts – this protects from any mechanical stress.
Providing optimum pack style flexibility, the Syntegon DCS distributes cookies onto belt legs for packing them flat or on-edge into pile, slug or tray packs. It is equipped to handle fluctuating production volumes, triggered for example by the failure of a packaging leg, intelligently.
combination of conveyor systems, pick-and-place solutions as well as infeed modules that allow for maximum efficiency during cookie handling. Packaging equipment experts like Syntegon then support them in realising their full potential in terms of efficiency without sacrificing gentle handling in the process. With decades of manufacturing know-how and industry knowledge under their belt, they help food manufacturers develop tailor-made solutions for their applications – so that biscuits and cookies make it into to their final destination whole and in one piece for the customer to enjoy.
For further information please contact Daniel Bossel Global Product Manager at Syntegon
Daniel.Bossel@
syntegon.com
Kennedy’s Bakery Production August/September 2023 11
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