Bahlsen’s goal was to cut down on plastic,
and Schubert responded by integrating thinner films for the inner flowpacks, further reducing material waste. This streamlined system, tailored to Bahlsen’s spatial constraints, is a testament to automation’s transformative role in the bakery industry. The heart of this upgrade is Schubert’s fully automated, flexible bar packers, which now handle every step in the packaging process: erecting, filling, and sealing the cartons with robotic precision. The line incorporates Schubert’s Transmodul transport robot, ensuring gentle handling to protect the delicate biscuits while increasing overall line efficiency. With each step seamlessly automated, Bahlsen is not only able to meet sustainability goals but also optimise cost-effectiveness. With a processing rate of up to 850 biscuit
bars per minute, the new system is not only efficient but adaptable. Robots handle the bars with such precision that the cartons are designed to be as compact as possible, eliminating excess space and reducing shipping volume. Additionally, the system’s versatility allows Bahlsen to package its treats in up to eight different configurations, a flexibility that’s invaluable in a competitive market.
True
automation isn’t just
about adding machines— it’s about developing interconnected systems that allow for precise control over each aspect of production”
Cost savings and flexibility For Bahlsen, the packaging overhaul is both a strategic and sustainable choice. The reduction in packaging material has led to significant cost savings, and the use of automated robots reduces human intervention, minimising errors and downtime. The automation also enables faster setup for format changes, which can be completed in just 20 minutes—ideal for meeting varied product demands. This innovative line doesn’t just cut costs
and support the environment; it also enhances product consistency and improves turnaround times, essential in today’s fast-paced marketplace. Schubert’s robots work in sync to streamline packaging without sacrificing product integrity, a must in the delicate world of bakery goods. From Bonheur’s investment in Projective to Bahlsen’s partnership with Schubert, bakery manufacturers are reimagining what it means to be efficient, cost-effective, and environmentally conscious. These partnerships and technological advancements underscore an exciting shift: one where cutting-edge automation, energy-efficient systems, and smart packaging solutions drive growth while addressing the critical need for sustainability. For bakeries around the world, these developments signal a turning point. By leveraging the expertise of firms like Projective and Schubert, manufacturers are not only meeting rising consumer and regulatory expectations but also positioning themselves as industry leaders ready to thrive in a future where every kilowatt, drop of water, and gram of plastic matters. The message is clear: with the right blend of technology, sustainability, and strategy, bakeries have all the ingredients they need to rise to new challenges and serve up a future that’s as sustainable as it is sweet.
bakeryproduction.co.uk
Kennedy’s Bakery Production October/November 2024 27
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