The company needed technology that was able to process a range of pack formats for muesli and extruded cereals, under the brand name Fleks.
Peter Kölln technical project planner Denise Stoldt told BakeryandSnacks the Ishida X-ray inspection system is more accurate than a competitor model in its production department.
140 packs a minute
“The crucial factor is the enormous flexibility offered by the new line, which allows us to process a wide range of products on one system at high speed,” she said.
Ishida installed two CCW-RS multihead weighers, an IX-GA-4075 X-ray inspection system and a DACS-G checkweigher to handle various types of muesli and Fleks in different pack formats, with fill weights ranging from 325g to 1kg.
The line is capable of speeds of up to 140 packs per minute (70 weighments per minute per machine), with accuracy to within 0.5% of the target weight.
The only factor that prevents the weighers from achieving a higher output is the low fall speed of the light products.
“The system is running really smoothly in three-shift mode and has reached a stable output,” added Stoldt.
Anti-leak hopper doors
The pre-mixed muesli and Fleks are fed via a bucket elevator onto the two weighers. The cereals pass through inlet chutes onto the dispersion tables, where the sensitive Ishida loadcell with feedback to the infeed ensures there is an even and consistent product flow to the radial feeders.
All hoppers have anti-leak hopper doors to prevent fine product from leaking during the weighing process.
According to Stoldt, one of the challenges created by the fully automatic weighing of cereal products is the amount of dust generated.
“The CCW-RS weighers ensure gentle product flow and all contact parts are electrostatically polished so dust traps are minimized, preventing product residues coming loose and landing in a different pack as unwanted cereal clumps,” she said.
“In addition, to prevent dust pollution in the factory, the weighers are housed in a special dust enclosure with air extraction.”
After weighing and filling, the packing line, which is split, converges and the products go through an inspection process.
The Ishida IX-GA-4075 X-ray inspection system detects stone, glass and metal – foreign bodies that can occur in products containing raisins and nuts.
Bags containing product clumps are eliminated using an airblast nozzle.
Products undergo a further quality check before end-of-line packing. An Ishida DACS-G checkweigher rejects packs that do not meet the correct specifications.
Aluminium-coated film is used for the Fleks, while muesli products are packed into clear plastic bags and later into cardboard boxes.