At interpack this year Syntegon will be presenting a flexible line concept for packaging sensitive baked goods, spanning from product distribution to case packaging.
The integrated packaging system they are showcasing is equipped with numerous technological innovations.
“Manufacturers looking for an efficient solution in the medium output segment will find from Syntegon fully automated lines from a single source – including gentle handling, sustainable primary packaging and high format flexibility for different products,” explained Stefan Schulze, Product Manager at Syntegon.
The Syntegon DCG (short for ‘Distribution Continuous Gentle’) distribution station will be making its debut at the show. The new station continuously discharges 400 sliced cakes onto the downstream packaging leg at 18 cycles per minute. Using the pullnose method, the DCG discharge belt lowers and deposits the cakes gently and in a controlled manner onto the downstream cross belt.
Thanks to its gentle handling, the distribution station is ideally suited for delicate baked goods or sticky bar products.
“When we were developing the Syntegon DCG, we placed particular emphasis on flexibility and hygiene. Depending on production requirements and layout options, different modules can be easily combined with each other,” Stefan added. “In addition, the distribution station’s open design makes it easily accessible. Sloped surfaces help catch product residue and keep the production environment clean.”
Once the sliced cakes have been discharged onto the packaging leg, the FIT inline module continuously feeds them to the flow wrapping machine. Linear motors ensure gentle handling of the sensitive products.
The sliced cakes are then packed by the robust and reliable Pack 403 flow wrapping machine. Thanks to fast and tool-free format changes, it is suitable for a wide range of products. At interpack, the Pack 403 will show how to pack 400 cakes per minute in gusseted flow wraps.
The subsequent robotic pick-and-place platform ensures a high degree of flexibility, and has been tried and tested in different systems since 2022 and will now be shown as part of the exhibited line with a new grouping and loading function.
Primary packaged cakes are inspected and continuously placed into the robot’s collation chain. Defective packs are discharged instantly. A robot arm picks the individually packaged sliced cakes at 50 cycles per minute.
The products are then separated at the gripper into groups of two by four. The robot deposits the grouped products in the integrated bucket chain of the endload cartoner. The speed of the robot and cartoner’s infeed chain are synchronised.
With this showcased application, Syntegon said, manufacturers benefit from the scalability and flexibility of the company’s robotics platform. In addition to fast system integration, all RPP versions also meet IP65 protection and high hygiene standards.
The company’s software, Synexio, contributes to monitoring of the equipment mentioned. The software collects, evaluates and visualises machine and production data.
Synexio will be offered in three, consecutive packages. The basic package ‘Monitor’ visualises various KPIs and thereby improves product transparency.
“Now that our customers are successfully implementing the basic package, we are ready to upgrade to the next level,” said Elisa Hein, Product Manager Expert Services at Syntegon. “With this [second Synexio package], we are delving deeper into the details: Besides machine availability, we can now also identify specific potential for improvement, for example by visualizing the most frequent reasons for stops.”
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