Confectionery

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Chocolates

Roshen is one of the most successful companies in the Ukraine and the largest producer of chocolate in the country. Its high quality standards and appealing product presentation are impressive across the board. Schubert top-loading technology handles automatic loading into the sophisticated packaging. The transport robot being used, the Transmodule, was once again the key to success. See for yourself! Please note that the products and cartons in the photos are for testing purposes only.

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Chocolate Bars

Whittaker's is not a typical Schubert customer. The relationship between the Whittaker and Schubert families has been developing for over two decades. It all began during a visit to the Schubert trade fair stand during the Interpack show in 1990. Visionaries Brian and Andrew Whittaker were thrilled with Schubert SNC-F2 robots and recognised the future potential of flexible packaging technology. Ever since, they have regularly invested in Schubert packaging technology. Today, the successful New Zealand company uses Schubert lines spanning multiple generations. According to Brian Whittaker, Schubert lines first commissioned over 20 years ago are still running three shifts per day and have paid for themselves many times over. Besides the very low life-cycle costs, key elements such as high efficiency and size flexibility have been decisive.

Whittaker's latest jewel is a compact TLM packaging line for cartoning and palletizing wrapped and sleeved chocolate bars. TLM-F44 robots are used to group the chocolates. As a result the high-quality products are not driven into grouping chains at high speed and thus physically stressed, rather they are gently placed one on top of another one at a time to form stacks, which are then placed in Transmodule size parts. Quality control by the Schubert scanner is fundamental for the high quality demands placed on the product packaging. In addition to detecting the position and rotary orientation of the individual products, what's arguably the world's current best scanner also provides valuable information on the products. Only products of perfect quality are packaged. This reduces quality complaints and increases line efficiency, as defective products could also cause machine faults.

The size conversion for grouping is carried out at the push of a button to select the size. If the basic dimensions of the products change, the Transmodule plates are exchanged. Erection of the wraparound blank is carried out in a Schubert standard TLM erecting machine. In a second sub-machine, the product stacks which have been formed are transferred from the Transmodule into the erected blank by a TLM-F2 robot. The sub-machine for closing the carton blanks also handles the function of transferring the finished package from the Transmodule to the discharge belt. This belt brings the package to the Schubert TLM palletizer in the next room. We at Schubert are proud to have made a small contribution to the success story that is the Whittaker's family business and are looking forward to providing additional installations to one of the most beautiful countries on the planet.

Information on output and packaging variety: 200 and 250g chocolate bars of up to six different thicknesses (the length and width stay the same) are inserted into five different one-piece blanks (wrap-around) horizontally upright or four different twopiece blanks (tray and lid) vertically upright. The line handles 240 cooking chocolate bars per minute, i.e. 20 cartons (primary packaging) per minute or three pallets per hour. The maximum pallet height is 2,115 mm, or 522 primary cartons per pallet.

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Cakes

We presented our idea of the mother tray at Interpack 2011. At the time, we were already working on an order for Manor Bakeries in England. The result is exceedingly good. Imagine two simple tray destackers each destacking 16 trays per minute. This translates to 2 x 450, or 900 individual trays, per minute. The individual trays are shaped so that three individual packages are connected together and can be broken apart and opened individually as the consumer wishes.

The mother tray is filled with tasty cake slices in line part 1 by TLM-F44 robots. The total outputis 900 cake slices per minute. In line part 2 , which is a TLM sealing and punching machine, sealing with a cover film is then carried out using ultrasound while individual trays are punched out. In line part 3 , which is a TLM final packaging line, packages of 48 individual units are produced from 6-pack sleeves and sales cartons. Should problems occur in line part 2 or 3, the mother trays can easily be destacked and buffered in the intermediate term.

To grip the sticky cake slices, a special gripper had to be developed for the TLM-F44 robot.

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Puffed-Rice Bars

Two Fuji flowwrappers in the foreground of the photo are supplied with puffed-rice bars by a TLM F44 picker line, which appears in the background. Of special note here is the chain speed of the two flowwrappers. Both machines run at a chain speed of 1,000 mm per second. The TLM F44 pick and place robots are able to place a puffed-rice bar ahead of each flight. 1,000 mm per second corresponds to a rate of 9.1 bars per second or 550 bars per minute with a flight spacing of 177.8 mm.

Alternatively, plastic trays can be filled with puffed-rice bars and then be flowwrapped on the same packaging line. In TLM packaging machines most functions take place in the machine software. This is what makes it possible to achieve performances and ensure the flexibility required for continual adaption to market changes at the same time.

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