Innovative full-servo product transfer for gentle handling
Easy access, cleaning and maintenance
Suitable for a wide range of product shapes and slug lengths
New Richmond, WI, – At the International Baking Industry Exposition (IBIE) and PACK EXPO International 2016, Bosch Packaging Technology will debut its biscuit on edge packaging system, now available in the U.S., for the efficient and flexible packaging of biscuits and crackers in slug packs. The modular system consists of a loader, a transfer unit, a feeder and the Pack 301 LS (Length Slug) horizontal flow wrapper. The Pack 301 LS has been developed as an addition to the Pack Series of horizontal flow wrappers, which range from entry level, hand-fed machines to fully automated solutions. It is designed to help manufacturers meet the increasing market demand for biscuit wrapping together with premium product quality. “Due to the strong industry demand for flow wrapped biscuits on edge, Bosch offers a system that enables biscuit producers to get ahead of the competition and enhance flexibility,” says Paul Jenks, director of sales and marketing at Bosch Packaging Technology, Inc. “The highly versatile system allows for fast changeovers and easy maintenance to help manufacturers increase adaptability and increase their competitive advantage.”
At PACK EXPO International 2016, the biscuit system will be exhibited in combination with vibratory channels, the new Paloma D3 robotic feedplacer as well as the Enterprise endload cartoner, supplied by Kliklok-Woodman, which belongs to Bosch Packaging Technology.
Innovative features for reliable product handling The system, including a Smart Measuring Loader for slug portioning, has been designed specifically to ensure gentle product handling for delicate and brittle biscuit-type products – even at higher speeds. Transfer points from the loader to the cross chain, from the cross chain to the infeed chain and further into the film tube generally pose the greatest risk for product damage and breakage. Due to the full-servo execution, the Smart Measuring Loader allows for smooth placement of the portioned biscuits into the cross chain. The Smart Transfer Unit features pre-acceleration for optimal synchronization with the infeed chain. It therefore eliminates impact on the product when bringing it from the cross chain into the machine infeed, ensuring gentle, reliable handling. To keep the biscuits in an upright position while being transported into the film tube the biscuit portion is supported by a counter holding pin. The position where the counter holding pin comes up can be easily modified by the operator via an adjusting knob. Between the folding box and the cross-sealing station the slug is guided carefully by side belts or chains towards the cross-sealing station. Depending on the product characteristics, operators can easily exchange side belts with side chains and vice versa for enhanced flexibility and optimal support. All of these innovative features ensure that products are kept under control during the complete packaging process. Additionally, the narrow design of the cutting head improves sealing performance and creates tight seals.
Total Productive Maintenance Designed for ease of operation and with the concept of Total Productive Maintenance (TPM) in mind, the system has been laid out to be accessed from all sides for smooth operation, fast and easy cleaning, and low maintenance effort. The cross chain features a spring loaded chain tensioner with visual feedback, allowing the operator to easily check whether there is optimal chain tension or it should be adjusted. Machine parts in contact with the product are made of stainless steel, meeting today’s hygienic standards. The open design allows crumbs and rejected products to fall through or be removed easily. All of these features add to operator friendliness and boost machine uptime and availability.
Designed for maximized effectiveness All aspects of the biscuit packaging system are designed to minimize downtime and enable stable output at high production speeds. To increase effectiveness, the complete biscuit feeding and packaging solution is operated by a single Human Machine Interface (HMI), enabling operators to monitor all process functions precisely. In addition, it allows quick format changes and thus enhances production flexibility. Whenever a product is missing, the machine and the infeed stop to avoid empty packages. Thanks to optimized interfaces, the integrated system can be provided with all required upstream equipment including vibratory channels, offering a complete solution from a single supplier.
Flexibility for product shapes and layout configurations Developed to address current and future market requirements, the system is capable of packaging rectangular, square and round products, as well as sandwich biscuits. Depending on the manufacturer’s requirements, the solution can be equipped with up to ten vibratory channels. The modular design allows for scalable solutions and layout flexibility, enabling manufacturers to easily expand their production capacity.
To learn more, visit Bosch at IBIE, Las Vegas, Nevada, from October 8 to 11, 2016 at booth #10305 and at PACK EXPO International, Chicago, Illinois, from November 6 to 9, 2016, South Hall, booth S-3514, co-located with Pharma EXPO.
Contact: Jana Ujevic, phone: +1 715 243 2503
Contact person for press inquiries: Jela Grubesa, phone: +49 711 811-58507
The APAS workstation: people and robots working hand in hand
Connected automation reduces workload: focus on the operator
IT Shopfloor Solutions: scalable automation system to make production and logistics safer and more transparent
Stuttgart/Munich – At the international trade fair Automatica 2016, Bosch presents Connected Shopfloor Solutions, a combination of hard- and software solutions for flexible, networked manufacturing (hall A5, booth 306). These solutions are already in use today, at Bosch and elsewhere: human operators and mobile assistance systems are working hand in hand without the need for safety fences, while IT systems analyze, report on and control a wide range of production processes. Yet people remain at the center of it all: “Given the spectrum of work processes in today's manufacturing, people are now needed more than ever as decision-makers and overseers,” explains Volker Hartmann, Deputy Vice President Business Unit Assembly Systems and Special Machinery at Bosch. “Our robots collaborate with humans and help them with tasks that are potentially unsafe, overly simple and monotonous, or ergonomically challenging. Humans and machines complement each other.”
The APAS workstation adapts to operator needs The APAS workstation shown in Munich is consistently focused on operator needs. The first standardized workstation is equipped with a collaborative robot kinematics system (APAS safekin), which allows direct and safe man-machine collaboration. Protected by a sensor skin, the integrated robot kinematics system successfully combines the inimitable skills of the human hand with the strength, the tirelessness and precision offered by robots and delivers more efficient processes. The operator can enjoy an individually tailored, ergonomically optimized work setting: the worktable height and lighting automatically adjust to the operator. The flexible APAS workstation can be used with or without an integrated robot, and can network with further assistance systems as needed. The robot kinematics system, dubbed APAS safekin, can also be used independently of the mobile APAS base or an APAS workstation – then preferably as a fixed installation in a dedicated production segment. The new automation component can be easily integrated into a broad range of applications, allowing projects to be rapidly implemented, and existing facilities to be readily upgraded.
Collaborative robotics on the rise In addition to the APAS workstation, the APAS portfolio includes three mobile, collaborative assistance systems, all of which can interact with human operators without a safety fence. The APAS inspector is an automatic testing device for visual inspections, equipped with a high-resolution, high-speed camera and innovative 3D mapping technologies. Thanks to interchangeable testing modules, the station can be used for high-precision surface inspections or completeness testing. In turn, the APAS flexpress is the candidate of choice for highly flexible, high-precision joining, one of the most common work steps in production lines. Its integrated safety features ensure that it can seamlessly support its human operator. The same is true for the APAS assistant, the first assistance system to be certified by the German Social Accident Insurance Institution (Berufsgenossenschaft). No robotics programming is needed: all the jobs are prepared, configured and managed using a graphic interface. As an available option, the APAS speedswitch can be set to monitor an extended vicinity and vary the APAS assistant's operating speed, depending on whether or not human beings are nearby. Provided no employees are nearby, the kinematics system operates at maximum speed. If someone approaches the APAS assistant, it automatically drops to a safe speed. The result: increased productivity without the need for additional safety measures.
Software from Bosch manages production processes Meanwhile, behind the scenes Bosch's IT Shopfloor Solutions deliver safety, flexibility and transparency throughout the production chain. For more than 15 years now, the modular and scalable software solutions have been continually refined within the company and used to manage hundreds of production facilities around the globe. Thanks to a broad range of software modules for Shopfloor Management, machinery can be networked regardless of the product or brand, product defects and the need for maintenance can be recognized early on, and production data can be analyzed in real-time. In addition, maintenance-relevant parameters can now be called up on a range of mobile devices.
Improved hygienic design recognized by globally renowned quality mark
Compliance with North American standards and regulations
Strengthening position on the U.S. liquid food market
Augsburg, Germany – Bosch Packaging Technology has introduced an extended portfolio of liquid food filling and packaging machines to the North American market, compliant with 3-A Sanitary Standards (3-A SSI). Recognized as the most detailed and stringent design guidelines available, the 3-A SSI – an independent, not-for-profit corporation – is specifically dedicated to advancing hygienic equipment design for the food industry. Bosch’s Ampack carousel filling machine for dairy food in pre-formed bottles and cups was recently awarded the 3-A certificate, while the company is working on extending the certificate to its inline filling equipment in the near future.
“We see growing market demand in the U.S. for simplified cleaning, minimized risk of cross contamination and reduced product waste,” explains Markus Schlumberger, managing director sales at Ampack GmbH, part of the Liquid Food product division at Bosch Packaging Technology. “These needs determine our commitment to hygienically designed filling and packaging equipment specifically tailored to the North American market.”
Answering the market’s needs As food safety regulations continue to strengthen, U.S. dairy producers are seeking ways to prevent product recalls. The 3-A SSI certificate gives them an assurance that their product will be handled hygienically through the filling and packaging process, contributing to high product quality and ultimately consumer safety. Manufacturers also benefit from easy cleaning – a positive side effect of sanitary design, streamlined to have fewer areas that can trap food and cause contamination. It is crucial that machines withstand vigorous cleaning and are self-draining, ultimately saving time and labor costs.
Customized solution for the North American dairy market After Bosch’s acquisition of Osgood Industries in 2015, a manufacturer of filling and sealing equipment for pre-formed containers in the food industry for liquids and pastes, the brand’s position in the North American market has already grown significantly. By extending the machine portfolio with the Ampack carousel filler complying with 3-A SSI standards, Bosch is taking another forward step towards adapting its portfolio to regional customers’ requirements, reassuring North American dairy manufacturers that equipment has been verified by an objective, independent organization and bears the globally-recognized quality mark. “Hygienic machine design allows food manufacturers to minimize downtime and product waste, ensure consistently high product quality and focus on what they do best – develop and deliver fresh and safe products to consumers. As a result of the certification, we can support our customers better in their journey towards safer dairy food,” concludes Markus Schlumberger.
Contact: Markus Schlumberger phone: +49 8231 6005-918
Contact person for press inquiries: Jela Grubesa phone: + 49 711 811-58507
Flexible use: compatible with all common filling systems
Optional 100% in-process control
Bosch Packaging Technology, a leading supplier of process and packaging technology, presented the latest generation of the ALF series at Pharmatag 2016 on May 10 and 11 in Crailsheim, Germany. In addition to many detail improvements, the new filling and closing machine offers an increased output of up to 600 ampoules per minute. “Not only regarding its output, the new ALF 5000 is situated in the high-performance range,” Tobias Göttler, product manager at Bosch Packaging Technology, emphasizes.
Optimized design, high process safety The improved pharmaceutical design of the new ALF 5000 is clearly visible: the machine table top is conceived without steps and interfering edges, providing a better sealing from the sterile area. Moreover, the machine’s improved accessibility ensures easy and reliable cleaning. In addition to the common right-hand version, the ALF 5000 is now also available as left-hand version, which enables optimal adaption to existing production sites and workflows such as internal itineraries.
„During the development process, we put special emphasis on even higher process safety,“ says Göttler. “For instance, the ampoule heads are removed sidewards during closing instead of from above.” This avoids machine movements above the open ampoules, making the process safer and more reliable. For a particularly gentle processing, it is now possible to use a carrying rake transport system that slightly lifts the glass containers to prevent them from rubbing against the machine guide.
Maximum flexibility Whether four, six, eight, ten or twelve filling points – all established filling systems such as peristaltic pump or time-pressure-filling system can be used with the new machine. In its combi version, the ALF 5000 optionally processes injection bottles in addition to ampoules, which further increases production flexibility for drug manufacturers and contract packers, combined with easy changeovers. As an option, customers can also choose between a statistical or a 100% in-process control, as well as different infeed and outfeed versions.
“We have used our expertise from more than 2,000 delivered filling and closing machines for ampoules and combined it with our successful technology from other machine series,” Göttler explains. “The result is an especially flexible solution that can be tailored to specific customer requirements.” Due to its compact design, the ALF 5000 is suited for wall mounting and integration into barrier systems without difficulty. Following Bosch’s pharmaceutical line competence approach, the new filling and closing machine can be combined with upstream and downstream equipment to form a complete line.
Contact: Tobias Göttler Telefon: +49 7951 402-619
Contact person for press inquiries: Christin Pönisch Telefon: +49 711 811-58502