Innovative packaging solutions from Schubert for sophisticated bakery products

2024-05-03

The baking industry is facing a fundamental change. Like many other industries, it is being affected by current economic conditions such as rising energy prices, supply bottlenecks and inflation. As if that were not enough, there are fewer and fewer classic artisan bakeries, as they are being displaced by large industrial bakeries. Furthermore, most market participants are struggling with a lack of personnel. Therefore, tasks that were previously executed by hand have to be executed by machine as soon as possible. Although, to this day, baking processes have become quite automated, this is not yet the case in packaging processes. On the other hand, consumers increasingly want new product variations and demand greater sustainability. In this dynamic environment, companies need reliable support. As a packaging specialist with many years of experience, Gerhard Schubert GmbH is a partner that accompanies companies on the difficult path of profitability, efficiency and automation.

Pick and Place robots pick up baked goods and place them with millimeter precision.

The image shows Pick and Place robots that group cookies into piles before later packaging.

In addition to a rapidly evolving market environment, the challenges for bakeries also lie in the production and packaging processes themselves. For example, many bakery products are especially sensitive to handling, while others must be continuously chilled or modified atmosphere packaged. But, normally baked goods come straight from the oven. This means that the subsequent packaging process must run as smoothly as possible, since the baking process cannot simply be interrupted. With its innovative top-loading machines and individual consulting services, Schubert guarantees a precisely coordinated automated process. Both assortments with large production quantities and changing formats with small batches are managed without problems. And the transition from conventional packaging materials to more sustainable materials can be made quickly.

Packaging of bakery products: Schubert machines guarantee flexibility

All processes, from primary to secondary and tertiary packaging, can be combined at Schubert in a modular and at the same time compact packaging line. The various packaging phases can be flexibly integrated into the overall process. The Flowmodul bag form, fill and seal unit can be integrated at various points on the TLM line, for example to pack freshly baked products directly into tubular bags or later in the packaging process, for example to wrap baked goods in trays with tubular bags. Packaging in transport boxes and subsequent palletizing can also be integrated into a TLM line.

Companies themselves can print special tools adapted in 3D precisely to each format, such as the suction cup tool of the Pick and Place robot.

Thanks to the innovative sealing technology, recyclable films can also be used.

Workers with precision and accuracy: Pick and Place robots

An important task in Schubert’s packaging processes is performed by Pick and Place robots, which pick up bakery products and place them with millimeter precision into trays, cartons or thermoformed packaging. They achieve this thanks to the proprietary vision system developed by Schubert which, as a quality control system, reduces rejections, reduces costs and increases the efficiency of the entire packaging process. In addition to determining exact position, the Pick and Place vision system ensures that baked goods that do not meet quality specifications or are damaged are not picked up and processed again.

Furthermore, thanks to their individual tools, Pick and Place robots are extremely flexible when it comes to processing bakery products of different consistencies, shapes or sizes. With the comprehensive PARTBOX 3D printing system from Schubert Additive Solutions, bakeries can make the tools they need themselves quickly and easily through certified print orders. Likewise, Pick and Place machines prove their power when multiple assortment designs need to be processed, such as mixed cookie packs: Cookies enter the packaging line via several side conveyors, so bakeries can incorporate different product variants in the packaging process. From the infeed conveyor belts, Pick and Place robots pick up the baked goods and pack them into the appropriate assortment packages.

The Schubert Flowpacker wraps cookies individually, in stacks of two or three,

which can then be packed in cardboard boxes or, on the same machine, in multipack tubular bags.

Automation with the Schubert Flowpacker

The Flowpacker packaging machine allows you to pack all types of bakery products in different tubular bags. The flexible wrapper combines Pick and Place robots, the horizontal wrapping unit and a quality control system. It is easy to exchange baked goods of different shapes and sizes, as well as different formats and packaging materials. For example, the Flowpacker packs baked goods in tubular bags as soon as they come out of the oven, either one at a time, several at a time, or in stacks, or places them in different formations on trays or U-packs before packing them in the bags. tubular. Thanks to different sealing technologies, baked goods manufacturers also have the option of using especially thick high barrier films. With the horizontal wrapping unit it is also possible to use ecological films based on paper or recyclable monofilms without any problem.

The horizontal wrapping machine packs baked goods directly from the oven into tubular bags, one at a time, several at a time or in stacks,

or places them in different formations on trays or U-shaped containers before packing them into the tubular bags.

Responding to consumer demands with sustainable packaging for bakery products

The topic of sustainability also plays an important role for Schubert. To offer its customers the best possible advice, the packaging specialist has brought together her experience in the “Packaging Perspectives” program. Through consulting, packaging development and research, the technology leader wants to actively support bakery product manufacturers on their sustainable path to the future. In practice, this means that Schubert experts assist in material selection and packaging design for a machine-compatible and environmentally friendly packaging solution. Thanks to modular and automated packaging machines from Schubert, baking companies can not only react flexibly to new demands, but can also produce sustainably, thus positioning themselves for the future.