Pack Expo 2022: Syntegon to unveil IDH handling system for cookies and crackers

01 Sep 2022 --- Syntegon is gearing up to present a new solution for handling and portioning cookies and crackers at this year’s Pack Expo in Chicago, US. The company’s Intelligent Direct Handling (IDH) is based on a newly developed picker technology using linear motors. 

The flexible pick-and-place machine is designed to ensure gentle product handling and offer a compact design along with high output and the option of different loading products, both flat and on-edge. The linear motor bar forms the heart of the new machine, says Philipp Kathan, lead engineer IDH at Syntegon. 

“With a nominal 30 cycles per minute, the bar’s up to 40 pickers pick the products from the process belt and place them into a flow-wrapper infeed or into trays. Thanks to the slow and smooth movements of the linear motor movers, the cookies and crackers are handled with minimal mechanical stress and vacuum application – preventing breakage or damage to the product surface and ensuring optimal production efficiency,” he explains.

“The IDH picks the cookies directly from the process belt to keep the transport distances between the oven and the packaged product as short as possible, thereby reducing abrasion. Not only does this result in less product waste: but cleaning efforts are also minimized because less product residue accumulates in the system.”

The IDH churns out up to 800 products per minute.An integrated camera-based vision system detects the position and shape of the cookies and crackers on the infeed belt and transmits this information to the picker control system.

It can identify different product patterns or random arrangements and then process them. Each picker can be aligned individually to ensure all products are placed into trays or the infeed chain correctly.

Flexible and future-proof
IDH is also designed for pack-style flexibility. The number of vacuum pickers can be adjusted depending on the respective product and production volume. For example, manufacturers can increase the number of vacuum pickers to as many as 40 as process output increases.

When integrated into horizontal packaging lines, the Syntegon IDH also provides high pack style flexibility, claims the company.

“With the IDH, we are launching a compact and flexible solution that offers manufacturers a variety of options for packaging different product shapes and sizes,” explains Daniel Bossel, product manager at Syntegon.

“Cookies and crackers are picked directly from the process belt and placed into trays or the infeed of the downstream flow wrapping machine either on-edge or flat. This allowed us to omit long belts with chicanes and make the system design even more flexible.”

Compact design and high output
Overall, the Syntegon IDH is intended to make the packaging process less complex. Its space-saving design minimizes conveying distances and allows for new system layouts traditionally used in bar production.

Despite its compact dimensions, the IDH also achieves a maximum output rate of up to 800 products per minute – combined with its low reject rate and short downtimes; this ensures high overall equipment effectiveness.

“The Syntegon IDH complements the Syntegon RPP pick-and-place platform launched in 2021 perfectly,” Bossel explains.

“While the RPP’s delta robots pick up to 120 products per minute from a narrow belt, the IDH is ideal for higher volumes and particularly wide process belts. With our comprehensive portfolio for the cookie and cracker industry, we are able to offer our customers tailored system solutions with a low TCO from a single source.”

Syntegon will be presenting at Pack Expo from October 23 to 26 in Chicago, US. The company’s IDH will be showcased for the first time in combination with a Pac 202 flow wrapping machine at booth S-3514.

Edited

By Louis Gore-Langton

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