Syntegon gears up for world premier of packaging solution for delicate baked goods at interpack

By Gill Hyslop

- Last updated on GMT

Syntegon is showcasing a comprehensive system for handling and packaging layered cakes and other baked goods at interpack 2023.
Syntegon is showcasing a comprehensive system for handling and packaging layered cakes and other baked goods at interpack 2023.

Related tags Syntegon Technology interpack Packaging Bakery Automated packaging systems Robotics cloud based software

Thanks to its gentle handling, the German equipment specialist’s latest distribution station is ideally suited for dainty sliced cakes and baked goods.

Syntegon is gearing up to showcase its flexible line concept for packaging sensitive bakery goods at interpack 2023, taking place from 4-10 May in Duesseldorf, Germany.

The Syntegon DCG (Distribution Continous Gentle) distribution station continuously discharges 400 sliced cakes onto the downstream packaging leg at 18 cycles per minute. Thanks to its pullnose method, it lowers and deposits the cakes gently and in a controlled manner onto the downstream cross belt.

Once the slices have been discharged onto the packaging leg, the FIT inline module continuously feeds them to the flow wrapping machine, preventing a buildup of products along the way. Linear motors ensure gentle handling of the sensitive bakes. Each mover can be controlled and only accelerates when the product has been safely captured. This means the individual slices don’t come into contact with each other, which, in turn, reduces mechanical stress. In addition to gentle handling, the FIT impresses with its high flexibility: operators can switch between different formats at the push of a button via the HMI.

The sliced cakes are then packed in recyclable mono material film by the Pack 403 flow wrapping machine (at interpack, the demonstration model will pack up to 400 cakes per minute in gusseted flow wraps) and heat-sealed.

Thanks to fast and tool-free format changes, the Pack 403 is suitable for a wide range of sensitive products.

“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,” ​said Stefan Schulze, product manager at Syntegon.

Robotics platform

The subsequent robotic pick-and-place platform (RPP) gives manufacturers a high degree of flexibility.

According to Syntegon, the modular platform 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.

The primary packaged cakes are inspected and then placed into the robot’s collation chain. Defective packs are instantly discharged. A robot arm picks up the individually packaged sliced cakes at 50 cycles per minute, before separating them at the gripper into groups of two by four. The robot then deposits the grouped products in the integrated bucket chain of the endload cartoner.

In addition to fast and seamless system integration, all RPP versions also meet IP65 protection class and high hygiene standards. This means that it can even cater to applications with demanding cleaning requirements.

“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,” ​added Schulze.

“In addition, the distribution station’s open design makes it easily accessible. Sloped surfaces help catch product residue and keep the production environment clean.”

Compact and flexible

At interpack, Syntegon will also present its latest Kliklok BEC endload cartoner – which packs the pre-grouped sliced cakes at a speed of 100 cartons per minute – integrated with the RPP into one unit and connected via Ethernet for easy operation.

In addition to a new Human Machine Interface (HMI) 4.0, the BEC features improved controls in discreet CPU boxes, resulting in a compact layout. It also has an optimised drive system: With the switch to servo technology, various drive components can be optimally synchronised so the processes during loading are completely reproducible. In addition, the BEC uses the proven rotary carton infeed system, meaning there is less waste and downtime.

Syntegon’s Elematic 1001 TL Topload case packer is specially designed for ergonomic operation and can be easily integrated into any packaging line with a wide format range that allows it to be used for a variety of products. In addition, it processes pre-glued RSC and HSC blanks of different corrugated board thicknesses, which ultimately saves around 10% of energy and up to 40% of glue without sacrificing stability.

Support at fixed prices

Once ‘the basic package’ is successfully implemented, Syntegon takes it to the next level with cloud-based software that collects, evaluates and visualises machine and production data.

Senexio is available in three consecutive packages, starting with Monitor, which visualises various KPIs, thereby improving production transparency. Syntegon will present the second Synexio package – Uptime – at the trade show.

“With this, we are delving deeper into the details,”​ said Elisa Hein, product manager, Expert Services at Syntegon.

“Besides machine availability, we can now also identify specific potential for improvement, for example, by visualising the most frequent reasons for stops.”

Synexio is also part of the seven levels of service agreements that Syntegon offers for the maintenance of the machines. With each level, the scope increases – from basic service, including inspection and remote service, to guaranteed production performance of the machines. Level 4 offers total cost of ownership for the lifetime of the equipment.

Syntegon is a global forerunner in the development of sustainable packaging solutions that reduce energy consumption and pursue the ambitious goals of its clients to lower their emissions.

The Waiblingen-headquartered company has more than 160 years of experience in building integrated solutions that enable the safe production, processing, filling, inspection and packaging of bakery, confectionery, dry and frozen goods and dairy products. In 2021, the company posted €1.4bn in revenue and employs a 5,800-strong workforce to manage 30 sites in almost 20 countries.

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