In the packaging industry, operational efficiency is fundamental to optimize production and reduce operating costs. One of the essential pieces of equipment in flow-pack packaging lines are automatic feeding systems, responsible for ensuring a continuous and accurate arrival of products at the flow-pack wrapper. These systems allow you to maintain high speeds, improve process consistency and minimize waste, making them a key solution for manufacturers looking to improve their performance.
In this article we will explore what automatic feeding systems are, how they work and what benefits they bring to industrial production. In addition, we will detail the different feeders developed by Synchropack, from handling solutions to robotic technologies.
Operation of automatic feeding systems
Automatic feeding systems are designed to transfer products from the point of production (e.g. ovens in the food industry) to the flow-wrapper in an efficient and synchronized manner. Depending on the product characteristics, speed and accuracy required, different systems are used. Nevertheless, they fulfill three essential functions:
- Orientation and alignment: they ensure that the products arrive in the correct position at the flow-wrapper.
- Continuous flow and synchronization: they allow a constant supply of products without interruptions.
- Speed and control: they adapt the loading speed according to the production demand.
Synchropack’s feeding systems fall into three main categories: HFS (Handling and Feeding Systems), CFS (Conveyor Feeding Systems) and RFS (Robot Feeding Systems).
The choice of the most suitable type of load for the packaging process will depend on several factors:
- Type, shape and fragility of the product.
- Production speed and cadence required.
- Level of automation and synchronization with other machines.
- Available space and line layout.
- Hygiene and industry regulations.
HFS: Handling Feeding Systems
HFS receive the products, organize them into portions and transfer them in an automated way to the wrappers. Their main objective is to maximize the efficiency of the packaging process, reducing manual intervention and ensuring accurate and uniform product handling.
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PAF: Pile Automatic Feeder
This system forms and transfers piles of flat products, such as cookies and toast, from the production line to a flow-pack wrapper. It allows adjusting the number of products per pile without interrupting the process, compensating for thickness variations. Its modular design facilitates adaptation to different production needs and product types, optimizing the packaging process and ensuring efficient and synchronized feeding.
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SAF: Slug Automatic Feeder
Organizes products in vertical position and automatically transfers them to a packaging machine. Its modular design allows a scalable configuration (from 4 to 16 channels), adapting to the production flow. Portion length and product thickness can be adjusted without stopping the system. Compatible with flow-pack wrappers and tray packaging systems, it maximizes the feeding capacity of products such as cookies and toast, ensuring accuracy and efficiency in the process.
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RAF: Roll Automatic Feeder
This system groups and transfers long products, such as grissines, from the production line to the wrapper. It uses conveyors with sensors to count and organize the products into defined portions. Its modular design allows it to be adapted to different production capacities. Portions can be unloaded directly into the wrapper or into cardboard or plastic trays, ensuring a continuous and efficient flow in the packaging process.
CFS: Conveyor Feeding Systems
CFS automate the conveying, distribution and synchronization of products prior to packaging. Their integration into high production lines optimizes product handling and maximizes automatic packaging performance.
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RDS: Range Distribution System
This system automates the distribution of products at the end of one or several production lines, transferring them to secondary conveyors for orientation and synchronization with the packaging machines. Depending on the characteristics of the product, the system can align, discard, store or reinsert it into the production flow. It offers different configurations to ensure efficient and adaptable handling for various product types and production capacities, reducing manual intervention and improving operational efficiency.
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POS: Product Orientation System
Aligns products that arrive in disorder or with irregular positions, ensuring their correct arrangement prior to packaging. For this purpose, it uses conveyors with speed adjustments, fixed profile guides or motorized guides. Its design adapts to products of different shapes and sizes, ensuring a continuous and orderly flow to the next stages of the automatic packaging process.
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DSS: Different Speed Synchronizer
After distribution and orientation, this system adjusts the speed of the products to feed them correctly into the packaging machines. Different configurations are available depending on the required speed and pressure, allowing them to adapt to different production needs. Its objective is to ensure a smooth and synchronized transition, avoiding jams or accumulations, and improving the performance of the packaging line.
RFS: Robot Feeding Systems
Robotic feeding systems automate the handling of products by means of different types of robots, selected according to the weight, speed and level of precision required. They are designed to optimize production processes, improve efficiency and reduce manual intervention. Thanks to their versatility, these systems can be integrated into different industrial environments, offering solutions adapted to different volumes and types of products.
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ANTRO
These anthropomorphic robots are ideal for handling multiple products or heavy loads in medium production processes. Their design mimics the mobility of the human arm, with several joints allowing for high maneuverability. Available in five-, six- or seven-axis configurations, they offer flexibility and precision in automated feeding and handling tasks.
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SCARA (Selective Compliant Assembly Robot Arm)
Designed to handle light products in medium production runs, these robots combine X-, Y- and Z-axis movements with rotation, allowing for greater versatility in product orientation. They are ideal for individual packaging or grouping tasks, guaranteeing precision and speed in confined spaces.
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DELTA
These robots, known for their spider-like structure, are optimized for high-speed handling of light products. With 3, 4 or 5 axes of motion, they allow fast and precise movements, making them ideal for high-volume production processes.
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COBOT
These collaborative robots are designed to work alongside operators in low-production processes, without the need for safety enclosures. With up to six degrees of freedom, they can handle and feed light products in a flexible and safe manner, adapting to different work environments.
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CARTE
Specially designed for handling heavy products or long distances, these robots work in the Cartesian axes X, Y and Z with linear and precise movements. Their structure allows them to be adapted to different production needs, guaranteeing stability and precision in product handling.
Synchropack, a key player in the industry since 1988
Automatic feeding systems play a key role in optimizing flow-pack packaging processes. From mechanical solutions to advanced robots, each technology brings efficiency, precision and adaptability to production needs. Synchropack continues to develop innovations that improve the productivity and competitiveness of packaging lines, ensuring that our customers have state-of-the-art solutions for an increasingly demanding market.
At Synchropack we specialize in the design, manufacturing and installation of flow-pack wrappers and feeding systems. Our machines are designed to adapt to different production levels, product types and specific requirements, ensuring smooth integration into any packaging line. With these solutions we help to improve productivity and efficiency in the packaging process of our customers.
