You are currently browsing the tag archive for the ‘automated packaging’ tag.

Services_Preventive_Maintenance

Preventive Maintenance is basic to any operation that involves equipment with moving parts.  The concept reduces unplanned and costly downtime. Implementing a Bosch Preventive Maintenance Program is an investment to increase your operation’s reliability and product throughput and help to keep operating costs low.

Although many customers practice excellent Preventive Maintenance, there are also many customers who use the “don’t fix it until it breaks” method.  Would this method of maintenance work on your personal vehicle? Of course not! Don’t risk the income potential of your business by not performing maintenance. Not using a planned maintenance approach when serving your machinery is like burning operating capital.  With an ill serviced machine, your asset declines in value faster than depreciation and is costing you valuable production time.

Bosch has a cost-effective Preventive Maintenance solution for all of our customers.  Our customers have many reasons for using the Bosch Preventive Maintenance Agreement (PMA). Some use Bosch PMAs to establish a formal program that allows them to track the progress of maintenance that Bosch performs. Other customers use PMAs to help establish a program that they can eventually operate themselves, with only periodic assistance from Bosch Technicians, updates on factory training or other industry improvements. In any event, for whatever reason Bosch customers use PMAs, they experience a higher level of reliability from their Bosch Packaging Equipment with regular use of the PMA.

PMAs offer many tangible benefits:

  1. A 10% discount on labor for PMA visits
  2. One additional emergency service visit during the PMA period that also is eligible for the 10% labor discount
  3. A 5% discount for parts recommended by the technician during the PMA visit and purchased within 30 days.
  4. Direct access to the assigned technician for emergency help if you need it
  5. Opportunities to train your existing staff on the Bosch Packaging Equipment

Contact your Bosch Representative and ask about the Bosch PMA. You can’t afford not to!

Also for more information download our brochure Preventive Maintenance Agreements.

  • Bosch’s new VFFS test lab in New Richmond, WI.

    „ $850,000 expansion facilitates full integration and testing of vertical bagging lines with secondary packaging equipment

  • „  Temperature and humidity control to simulate production conditions
  • „  In-house training for customers provides familiarization prior to installation

The expansion of our state-of-the-art vertical form fill seal (VFFS) test facility in New Richmond, Wis was recently completed. The $850,000 vertical expansion, which started in  May 2012 and was completed in  December, helps us accommodate two full VFFS packaging lines that include secondary packaging, such as case erecting, loading and closing. With the expansion, we can now offer optimal product feeding to VFFS machines for extended runs, as well as temperature and humidity control to simulate each manufacturer’s specific factory environment.

Manufacturers across multiple industries, such as fresh and frozen food, as well as confectionery, utilizing our expanded  VFFS test facility can be assured that their line is fully functional prior to installation at their production site. From engineering, parts fabrication and assembly to line integration, testing and trouble shooting, Bosch offers its customers a full range of resources when using the company’s VFFS line testing facility in New Richmond.

Customer equipment training

Via this expansion, we enhance our ability to provide customers access to equipment training and familiarization, which results in a smooth start-and ramp-up of their production. Training can range in complexity, from simple hands-on operation during the Factory Acceptance Testing (FAT), to in-depth Packaging Machinery Manufacturers Institute (PMMI)-certified classroom training for operators and mechanics, including PMMI-certification testing at the end of the training modules.

“Bosch’s New Richmond test facility provides customers with the assurance that their vertical packaging line has been fully tested and is ready to go,” said Eric Aasen, vertical product line manager, Bosch Packaging Technology. “This demonstrates our commitment to ensuring that our customers achieve maximum efficiency and profit.”

VFFS line featuring delta robotic case packing at the expanded test facility.

Global product line, local support

The expansion is part of our strategy of offering a top notch global product line with local support. We supply a wide range of VFFS technologies to suit various market needs, including both continuous and intermittent vertical baggers with its SVE and SVI series, as well as heat and ultrasonic sealing technologies. Our vertical baggers have the flexibility to produce numerous pack styles, including pillow, gusseted, stand up, full four corner seal block bottom, and doy bags; as well as special bag styles and various opening and reclosure aids, on a single machine without adjusting machine height. This allows manufacturers to quickly adjust to changing market demands. We also offer secondary packaging equipment that can be integrated into fully automated lines specific to customer applications, known as Module++.

Sustainable design

We also made sure that the expansion included several sustainable elements, such as windows with low-emissive (Low-E) glass, which reduces energy consumption by allowing light to pass through while reflecting heat, as well as T8 fluorescent lamps with electronic ballasts that produce more light per watt, run cooler and last longer. In addition to meeting building envelope insulation requirements, we also incorporated its highly efficient point-of-use water heater. Other sustainable features include variable frequency drives (VFD), used to further reduce energy consumption for the crane and hoist system, and the high efficiency combination air handler and air conditioning unit.

Bosch’s New Richmond facility serves North America’s various packaging sectors, including the confectionery, bakery, fresh food, frozen food and pharmaceutical markets, and employs more than 270 people. In 2004, Bosch acquired the facility from Doboy, Inc., whose roots in food packaging begin in the 1870s.

Partnership with Bosch Accelerates ProductionEndangered Species Chocolate Squares

Endangered Species™ Chocolate expects more than a 230 percent boost in output by using Bosch’s Pack 401 horizontal flow wrapper, enabling it to meet increasing demand for its chocolate bars. As evidenced by its name, the premium chocolate company donates 10 percent of its net profits to species and habitat conservation efforts.

The company has been using Bosch machines since opening in 1993. As more and more consumers were craving its 0.35-ounce Organic Chocolate Squares, known as Chimp Mints and Bug Bites, Endangered Species needed to increase production capacity. The Pack 401 enabled production to jump from 120 pieces per minute to 400 pieces per minute.

“The Pack 401 wraps our products faster than we can currently produce them,” said Bryan Fuller, Director of Operations, Endangered Species. “This positions us for our anticipated growth over the next few years.”

Previously, defective packaging had to be manually sorted and discarded.  The Pack 401 features sensors that automatically detect and reject inadequate products and packaging, such as empty packages, uncut packages, or packages with film splices, which increases efficiency and saves on labor costs.

“Our conservation mission is the core of our organization and we fully trust that Bosch’s technology will produce results,” Fuller added. “Higher profits and reduced waste mean more donations to our not-for-profit partners.”

As the company experienced tremendous growth in production, it needed a machine with simplified cleaning and maintenance to ensure product safety and remove all traces of allergy-causing ingredients. “The Pack 401 is an expertly planned machine – every section is easy to access and clean,” said Fuller.

“We always enjoy helping our customers reach their production goals and it’s even sweeter when this also benefits important causes,” said Paul Garms, Marketing Manager, Bosch Packaging Technology.

Endangered Species’ previous solution required that the chocolate squares be manually transferred from their molds to the primary packaging machine. The Pack 401 automatically directs the chocolates from the mold line to the flow wrapper without human intervention, allowing the company to redirect labor to higher skilled positions.

Solar powered IQF (Individually Quick Frozen) vegetable processing and packaging facility in the USA relies on efficient Bosch VFFS baggers to meet its quick changeover times and reliability demands.

Seabrook Brothers & Sons is a third generation family owned and operated business that processes and packages 150 million pounds of frozen vegetables per year.   Located in the “Garden State” of southern New Jersey, they are ideally positioned to quickly supply the major metropolitan areas along the east coast of the U.S. with a wide range of frozen vegetables.

As a co-packer, the demands on their operation are diverse, with over 1,800 SKUs produced in their Seabrook, NJ facility.  Seabrook runs two 10 hour shifts per day, six days a week and on average has 3 to 4 changeovers on each line per shift.  That’s up to 288 changeovers per week across Seabrook’s 6 packaging lines.  These changeovers affect their Vertical Form-Fill-Seal operations dramatically.   It was the need for rapid changeovers, ability to handle a multitude of films with no tweaking or loss in speed, and basic reliable operation that lead Seabrook to purchase a Bosch SVE 2510 continuous motion bagger after trying two other VFFS bagger brands.

As William “Wes” Seabrook , Vice President Engineering, at Seabrook explained “Every machine you can make work if you have time to tinker with it.  We don’t have time here.  We need to set it up for the next product and run.”  Just like their customers, Seabrook doesn’t carry a lot of stock, so if they are to meet their customer’s demands they need to package and ship without interruption and the Bosch machines give Wes the quick changeover and reliability he needs.  “After we tried the first Bosch bagger we loved it,”  notes Wes, “The ease of operation and reliability of the Bosch bagger lets us meet our customer’s demands.”

Seabrook Farms uses state-of-the-art equipment throughout their facility.  The bagging lines primarily uses Gough Econ bucket elevators to feed Yamato scales above the Bosch baggers.  Safeline metal detectors and check weighers on the take-away conveyor round out the bagging lines.   Wes specifies this equipment to Bosch and then Bosch executes and integrates the entire line, including the scale platforms, for Seabrook.   “This is a big help for us” notes Wes, “We don’t have to worry about the drop heights from the scales to the baggers, or anything else about the line integration.  We know when we get it all from Bosch it will be optimized and running together smoothly.”

Operating a state-of-the-art facility isn’t restricted to Seabrook’s packaging lines.  Their approach to powering their facility is also state-of-the-art.  IQF processing is an energy intensive operation, so Seabrook looked for new, environmentally friendly technologies to help with their energy needs.  It started with purchasing generators so they could participate in peak shaving, synchronized reserve, and demand response programs with their local utility.  Then they took their energy program to the next level and installed 21 acres of solar panels next to their processing facility in Seabrook, NJ.  The solar farm generates about a third of Seabrook’s total electricity requirements and reduces greenhouse gas emissions by 6, 989 tones per year.

To increase outputs or lower manufacturing costs, manufacturers are often challenged with the decision of selecting between robotics or product distribution conveyors when opting to automate their lines. As a supplier of robotics, conveying technologies and integrated packaging lines, Bosch discusses the criteria in selecting an optimal feeding solution in a new white paper – “Packaging Line Automation – Robotics or Product Distribution Conveyors?”, recently featured on Snack Food and Wholesale Bakery. The white paper provides unbiased advice for manufacturers and highlights key considerations for choosing between robotics and product distribution conveyors for feeding.

For example, the paper advises on different pack configurations, such as for a simple bar package or a more complicated cookie stack. For more information, click on the link above.

Join 922 other followers

Welcome

Welcome to the Bosch Packaging blog for North America where you can find the latest news, tips, product updates and event information specific to the food industry!

For support and machine information on Bosch packaging equipment in North America, please visit our contact page.

Find what you're looking for and easily browse available content with our Content Directory.

Navigate to other related sites through our Links page.

New! You can now subscribe to our blog and receive an email when a new post is published. Simply enter your email address in the box above.

%d bloggers like this: