Barry Callebaut focuses on the BEUMER packaging line:
Modernisation of the packaging line
As general contractor, BEUMER Corporation in Branchburg, New Jersey (USA) installed a complete packaging system, various conveying systems as well as a bagging system. With partner Behn + Bates America, a division of Haver Filling System, Inc., BEUMER equipped the line with the Integra system, a fully automated, completely premounted bagging system for bulk materials in the food industry. This system fills bags with cocoa powder and seals them. As part of the quality control process, the BEUMER belt conveyors transport the bags to a metal detector and a checkweigher. Here, bags containing metal or over- and underweight bags are rejected. After the palletising process, the stack press removes residual air from the bags, thus increasing the stack stability. When designing the packaging line, the handling of different batches on different-sized pallets was one of the challenges. For this reason the high-capacity BEUMER robotpac was installed providing excellent stack quality and load stability.
Commissioning of the high-capacity packaging system
The innovative BEUMER stretch hood is also part of the scope of supply. This high-capacity packaging system pulls a stretch hood over the palletised bag stack to protect the products against wind, rain and dust while providing ultimate safety during transport. The bag stack is completely packaged and transported to the take-away post. Thanks to the permanent tension force of the film in vertical and horizontal direction, the bag stack provides high stability – even if the cocoa powder settles in the bags, thus reducing the bag volume.
Sensors on the BEUMER stretch hood measure the height of the pallet. This automation allows for the calculation of different stacking heights as well as the optimisation of film consumption. The film is then cut and sealed. The formed hood is pulled over the complete bag stack forming a stable unit.
More safety and less film consumption
Since the modernisation, the workflow at Barry Callebaut’s packaging facility runs without any problems. The products are protected against wind, rain and dust. Besides the packaging capacity, the stretch hood technology provides improved visibility of the palletised products thanks to the smooth surface of the film hood. The material costs for packaging have been reduced since five to ten per cent less material is required, making this solution not only more cost effective for Barry Callebaut but an important contribution toward safeguarding the environment.