Circular economy thinking at the heart of Lush packaging design

Collect and recycle your own packaging

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A bring-back scheme returns used containers to Lush to be devolumized in-house (left hand) and the chips (or flakes) are converted to the source resin (right hand) for new pots and bottles

Pack Expo in Las Vegas, 28 to 30 SeptemberBosch to exhibit Two-in-One biscuit systemFollowing a highly successful field test with one of the leading international manufacturers of biscuits and cakes – United Biscuits, Bosch Packaging Technology will for the first time showcase on Stand C2800 its innovative Two-in-One biscuit packaging system at Pack Expo Las Vegas 2015, which will be held from 28 to 30 September. Launched at interpack 2014, it is the first system of its kind capable of pack style changeovers from slug to pile packs in less than three minutes, offering flexibility to biscuit manufacturers.
With format changeovers in less than three minutes and biscuit count changes in less than one minute, this Two-in-One biscuit packaging system lets manufacturers quickly adapt to changing consumer demands, and meet current and future market needsWith state-of-the-art product handling, horizontal flow wrapping and secondary packaging equipment, the system is designed for gentle and versatile wrapping and case packing of even the most delicate biscuit products. A customized field test at United Biscuits in Manchester, UK, effectively handled the primary and secondary packaging of the manufacturer’s McVitie’s Jaffa Cakes brand in different formats and sizes.

“What we found is that the very fast changeovers we saw at interpack actually can be translated into the industrial environment,” said Simon Breckenfield, strategic capability controller at United Biscuits. “During the field test, we were able to take 100% of the McVitie’s Jaffa Cake output through a single machine, and our view at the moment is that it has been a very successful project. It has allowed us to take our productivity and flexibility to the next level, as well as delivering a route-to-market solution our commercial teams were calling for.”

Circular economy thinking at the heart of Lush packaging design 3
Tracy Sutton’s consultancy, Root, helps companies identify the benefits of sustainable packaging design and efficient use of resources

The Two-in-One biscuit packaging system achieves high-speed, fully reproducible changeovers by using the same feeding components for both pile and slug packs, increasing productivity and uptime. It is the only system of its kind capable of changing the pile configurations in record time. No matter if 1, 2, 3, 4, 5 or more biscuits are required, pile packages with a maximum height of 50 millimetres (about two inches) are possible.

“We developed the Two-in-One biscuit packaging system as our response to a growing retailer and consumer demand for flexible packaging formats, like smaller on-the-go and larger family packages,” said Daniel Bossel, product manager at Bosch Packaging Technology.

A gentle handling philosophy across the line ensures minimized damage hazards and product contact, making the Two-in-One biscuit packaging system suitable for even the most fragile, brittle products. Additionally, three-dimensional product inspection technology detects broken biscuits and sorts them out. The hygienic design prevents the build-up of crumbs and allows for easy cleaning, facilitating a continuous production and maximized uptime. As part of Bosch’s Seamless Systems portfolio, the speeds of all line components are balanced to eliminate bottlenecks and optimize production flow, from distribution to secondary packaging. The integrated design concept with the same look and feel across the entire line with standard operating procedures makes the entire system as simple to operate as a single machine, reducing the risk of operator errors.

Complementing primary packaging, the biscuit system is designed for a wide range of case packaging formats for RSC or HSC cases (Regular and Half Slotted Containers) with retail-ready functionality. The case erecting, robotic loading and optional case closing units are all integrated in the case packer, resulting in a reduced footprint.

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