How do cookie factories ensure that each unit arrives perfectly packaged for its consumers? How is it possible for thousands of chocolate bars to be ready for distribution every day? The answer lies in the automation of packaging processes, specifically in automatic feeding systems.
These systems take care of a fundamental step in the packaging process: placing each product in the correct position to be wrapped by a flowpack machine. They are the key to smooth, hygienic and continuous production, even in demanding sectors such as industrial bakery, snacks or dairy products.
What are automatic feeding systems?
An automatic feeding system (also known as automated feeding system) is a set of equipment and mechanisms designed to receive, sort, group and transfer products from a production line (ovens, molds…) to a flowpack wrapping machine, without manual intervention.
The main objective of automatic feeding systems is to ensure that products arrive synchronized, continuous and in the right position to be packaged. This equipment can handle a wide variety of products of different sizes, textures, shapes or fragility. In the food industry they are often used to feed cookies, toast, sliced bread, bread sticks, crackers or other products into wrappers in a precise and efficient manner.
Types of automatic feeding systems
Synchropack has developed three different technologies for automating the feeding of products to flow wrappers.
- Handling and Feeding Systems (HFS). 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.
- Conveyor Feeding Systems (CFS). 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.
- Robotic Feeding Systems (RFS). 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.
In this article we will explore the different types of Handling Feeding Systems (HFS).
Handling and Feeding Systems (HFS)
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.
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.
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.
HFS in the food industry
Automating the feeding system in the food industry packaging process brings key benefits:
- Consistent and orderly product flow: HFS systems ensure that products arrive correctly oriented and spaced at the flowpack wrapper, avoiding accumulations and stoppages.
- Perfect synchronization with the packaging machine: working together with the flow-wrapper, the production rate is optimized and waiting times are reduced. Reduced breakage and waste: controlled and gentle transport protects fragile or deformable products, reducing waste.
- Traceability and process control: vision systems or control sensors ensure line quality control, avoiding the packaging of lost products.
- Maximum use of the wrapping machine capacity: by maintaining a constant supply, equipment efficiency is achieved without slowdowns.
Automation: complete lines optimize efficiency
Efficiency is not only measured by the speed of a wrapper, but by how smoothly the entire packaging system works as a whole. Fully automated lines, from infeed to final package sealing, allow greater control over production and the reduction of unforced errors.
Case study
Case 1: secondary wrapping of chocolate bars
Complete line for secondary wrapping of chocolate bars in stacks of 2 to 10 units. The line is composed of a PAF (automatic pile feeder) and a Pack 60 LTS wrapping machine.
Case 2: wrapping of frozen hamburgers
Complete line for wrapping frozen hamburgers in groups of 100 units at 20ppm. The line is composed of a POS (product orientation system), an SAF (automatic feeder of burgers on edge) and a special wrapper.
Case 3: wrapping of cookies in clusters
Complete line for the wrapping of edged cookies in clusters of 30 units at 80ppm. The line is composed of: a cookie distribution and stacking system, a double SAF (automatic feeder of cookies on edge), a STT (transfer of cookies on edge with tracking) and a Pack 900 RT BOE wrapper.
