For decades now the nation’s most favoured and adored biscuit based treats have been packaged via two insulated properties.
First you enter a niche store or large supermarket and find and identify with a heavily branded Bespoke Box (i.e. the first insulator). These catering Biscuit packets are usually long in depth, narrow in width and not too dissimilar to the functionality and protection of the Folding Cake Box.
This Coated Paper Case Storage then folds outwards and disposes of a Polymer Adhesive sealant (second insulator) capable of compacting the individual bakes into an aligned row. This hermetic heat sealant material is favoured by Global manufacturers on the market due to being ‘easy-open’, a binder and for providing;
‘Stronger hold, faster sealing, cleaner peel, or easier coating onto a substrate’.
http://www.dupont.com/
This advancement of the Bakery Film literally protects the foods from outside contaminations, and enhances the shelf life and fresh taste. These are all pros for the packaging system, but in the case of biscuit compaction it has one flaw. The Plastic Adhesives’ overall dimension is restricted to that of the Bespoke Box.
National treasures ranging from Mcvities Jaffa Cakes to Burtons Jammie Dodgers are constantly high in demand, thus require a lot of shop floor space on the shelves. The issue for the general dealer however is that both entities can only offer a single column (or average 12 items) of biscuits or cakes per packet (150g to 210g). This means stores have to bring in more batches to cater for the demand than they would for a boxing of two columns (Figure 1). This all in all costs them, the supplier, more thus they heighten the cost of the product in order to make a profit.
This means…you (the customer) are being penalised for the packaging cons.
However this problem could be a thing of the past. Innovators at the branch Bosch Packaging Technology (part of the Bosch franchise) have formulated a new Food Packaging Machine that collects around 24 biscuits (two columns worth) and compacts them into a single Sleeve. This procedure will be called the ‘Two-in-One Packaging System’.
This sounds as if a prospect with a lot of promise, but one could highlight that composing more produce into a single Adhesive Sleeve would only increase the length and in turn still require much shelf space. Bosch Packaging Technology have attempted to resolve this potential barrier.
Rather than doubling the Plastic and Box length, the manufacturers have engineered the production line in order to fit one as normal (vertical). The second culmination of biscuits will instead be halved as if two piles and placed in the same Sealant in an upwards motion. This means the packaging can contain double the amount of product with only minimal changes in packaging size.
Figure 1
Most convenience stores and supermarket chains will have to require much free room in order to shelf singles of branded biscuits. Bosch hope to double the mass of produce with little change to hoarded space.
Image taken from www.persuasion-and-influence.blogspot.com
In simple terms the technicians at Bosch headquarters seek to fit an average of 400g in cake weight within a cling and Bespoke box custom made for an average of 250g.
But it does not end there for the benefits of Boschs’ new ‘Two-in-One’ Machine!
The new technology will not only save overall room throughout convenience stores that service packaged biscuits and cakes, it also concerns the factory workers whom have to file the treats on the Step Control motor, seal them in the Adhesive and then fold that within the box. The usual Packaging Machines on the market operate with a single row pallet to output around 50-80 packs worth of biscuits per minute (according to Made-in-China.com).
That number does sound impressive, but remember the individual workers then have to collect, count and wrap in a constant notion (see Figure 2). This is called pile and slug. The pile is self-explanatory, whilst the slug is the part in which the columns are retrieved and then compacted. The problem with this is both phases of production have to be done at separate times, thus doubling workload and time management.
Bosch have highlighted this problem and intend to improve working conditions…
‘With this two-in-one line you can change over from one to the other or do both at the same time’
‘You can use the same feed and grouping to achieve pile and slug. It gives manufacturers more freedom’.
Daniel Bossel (Product Manager, Bosch)
Figure 2
Example of workers operating machinery at a biscuit factory.
Image from www.dunnyinjapan.wordpress.com
The achievements of this new systems appears to get better and better for all involved, whether it is the head manufacturer, factory worker, retailer or buyer. The Machine can endorse bulk at a higher amount and at a faster pace. This is great for the biscuit or cake productions who can churn out more produce at a quicker time rate, thus possibly sending out the additional batches to other retail suppliers not yet on the delivery list (i.e. more financial income).
The general customer can be even more overjoyed also…
‘It’s all about the count, meaning we are reducing the changeover time, we are faster, you can produce more biscuits, we can reduce the cost per pack’.
Daniel Bossel (Product Manager, Bosch)
What can happen however is that production companies can improve one component of their creation, but have to cut back on another in order to save costs. This has occurred many times in the past in which a heavier weight of property has been given per pack, but the packaging itself has decreased in durability and as a result become more vulnerable to moisture due to tearing and bumps and knocks.
This will not be the case for the ‘Two-in One- System’.
Robotic operated casing and loading of the biscuits/ cakes will add additional flow wrap such as Modified Atmosphere Packaging (MAP) and no gap/ no seal gusset folding. The new machines will package regular or half slotted containers ready for retail, all of which can either be taped or hot melt sealed if going straight to grocery store, or left unsealed if a third party is involved.
The machine also features a three-dimensional product inspection in which broken biscuits can be detected and discarded.
Figure 3
A single columned packet of Mcvities Jaffa Cakes with adhesive plastic and Bespoke box (upper) compared to the announced Bosch ‘Two-in-One’ Packaging System (lower).
Images taken from www.nearof.com and www.blog.boschpackaging.com
Plastic inserts for boxes