Interpack 2023: Syntegon to reveal flexible cookie and cracker packaging solutions

20 Mar 2023 --- Syntegon will showcase its horizontal packaging solutions for cookies and bars at Interpack 2023. Its Innovative Intelligent Direct Handling system offers format flexibility for cookies and crackers using a high-speed bar system for maximum efficiency with a wireless Human Machine Interface (HMI). 

The packaging for cookies and bars is made from paper and monomaterial as a more ecological packaging solution. The Syntegon IDH flexibly packages cookies and crackers in trays and flow wraps made of monomaterial. It utilizes new pick-and-place technology with integrated linear motors that handle products gently. 

The linear motors feature various feeding modules in both lines to prevent product damage during handling and boost flexibility. The line is equipped with a paper-ON-form forming shoulder and wraps bars in paper before placing them in glueless formed cartons in the TTM1 top load cartoner with an integrated lock-style forming station.

“With integrated linear motors, each picker can be individually aligned, allowing them to process even random product streams. The number of pickers can be increased to up to 40. At Interpack, the IDH achieves a maximum output of up to 800 products per minute – while still maintaining its space-saving design,” says Daniel Bossel, product manager at Syntegon.

PackagingInsights will report live from Interpack 2023 at booth B83 in Hall 8A.

Syntegon’s flexible line packages bars and biscuits in trays and flow wraps made of monomaterial.Live demonstration
Passersby can fill and seal the machine live for the first time at Syntegon’s booth at Interpack. The station offers manufacturers format flexibility by grouping and loading cookies in four formats – slug packs, pile packs, upright or piled cookies in trays – into the downstream infeed.

“Consistent gentle product handling is one of Syntegon’s strengths and especially important when processing sensitive products,” Bossel continues.

“Therefore the linear motors are also part of the downstream feeding module FIF. They move slowly and smoothly to protect products from mechanical stress, thus minimizing product loss.”

At Interpack, the FIF feeding module is integrated into an HCS form, fill and seal machine and feeds the cookies in piles, slugs or trays into the packaging machine. The HCS then wraps them in a recyclable film made of monomaterial and heat-seals all formats for airtight packs and product protection.

“Raising the bar” system
Syntegon’s linear motor technology is also a vital feature of the fully automated bar system. The bar system shows the packaging process from product distribution to secondary packaging in display cartons.

“Each gripper can be controlled individually and synchronizes optimally with the products – even with random streams,” explains Stephan Schuele, head of product management at Syntegon.

“It eliminates the need to accumulate the bars before they enter the packaging machine. This protects the products, reduces the line length and facilitates a reliable, continuous infeed even at high speeds.”

The discharge station provides a continuous product flow as bars can be temporarily stored on its waiting conveyor to ensure consistent feeding to the downstream HRM form, fill and seal machine, even if product volumes fluctuate temporarily.

Utilizing the company’s integrated high-performance splicer, it works to achieve accuracy during reel changes at speeds of 150 meters per minute.Syntegon works with paper packaging for cookie packaging at Interpack 2023.

Operating errors are automatically detected, increasing the availability and efficiency of the HRM – when processing alternative materials such as paper.

Glue-free packaging
After packaging, the integrated Sigpack TTM1 top load cartoner takes over the bars for secondary packaging. The PFI product feeding module is based on linear motor technology and identifies the position of individual flow wraps before gently and precisely loading them into the grouping chain.

Loading the bars into the grouping chain eliminates the need for additional mechanical parts, such as side guides, that could damage the paper flow wraps. The omitted format parts and the overall changeover concept of the TTM1 provide “quick and easy” format changeovers along the line.

“The new lock-style forming station further adds to Syntegon’s [environmentally] sustainable packaging initiatives. Cartons are formed without using hot-melt glue. This protects the environment and reduces the system’s energy consumption, minimizes cleaning efforts and sources of malfunction – and, last but not least, saves on consumables,” explains Andreas Schildknecht, product manager at Syntegon.

Human Machine Interface
Moreover, Syntegon will present a new wireless HMI that allows operators to access all available information and digital services anytime.

The new wireless HMI 4.0 is a new feature that “boosts efficiency,” particularly in large, fully automated systems. It allows operators to control and monitor the entire line via a single interface.

In the case of malfunctions and maintenance work, workers can immediately access all the essential information and instructions to restart the line as quickly as possible. Tool-free format changes on all line components further reduce downtimes.

Edited by Sabine Waldeck

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