A “light” plant for marzipan cakes

From the design of a particularly compact, highly automated and simple format changeover plant, designed to pack marzipan and chocolate cakes by Niederegger, a range of Schubert machines called lightline is launched. 

Based in Lübeck and with over 200 years of history behind it, Niederegger specialises in the production of gastronomic excellence: marzipan cakes in all shapes, gianduia chocolate and crispy chocolate truffles filled.

Since most of the specialities are intended for the trade - in particular the classic marzipan sweets, presented in elegant red, white and gold packaging - the German manufacturer has always invested in the automation of packaging processes. For a long time now it has relied on Gerhard Schubert GmbH (a leading name in the top-loading packaging machine market), which has supplied a TLM line for packaging the sweets in elegant cardboard boxes. What was missing, however, was the automation of the last stage of packaging, i.e. the insertion of the boxes into the shipping cartons. For about a year now, this gap has been filled with a new Schubert TLM machine, which enables transport packaging to be prepared with maximum efficiency.

Small footprint, maximum yield

The first problem faced by Schubert’s designers was the chronic lack of space in a production site transformed over time but never expanded. So, as Werner Schäfauer, Schubert’s sales account manager, recalls, the option was to choose a very compact solution to pack the complete boxes to be shipped in as little space as possible.

Secondly, the German manufacturer had to take into account six different formats to be processed on a single line (the Niederegger confectionery boxes differ in size and shape).

These considerations led Schubert to develop the first machine in the new lightline range, with the aim of offering a high quality TLM system for standard packaging tasks (carton forming, filling and closing), consisting of three types of machines: the case packer, the flowpacker and the picker line, all based on pre-configured TLM modules.

A compact machine for all formats

At Niederegger, folding cartons coming directly from the packaging line now enter the new machine crosswise on one lane, resting on one side. Here a grouping chain, equipped with quick-change forming cells, positions them vertically. Depending on the format, the number of boxes required is pushed by the transverse pusher out of the chain and brought together in a block, which is picked up by an F2 robot and placed in the carton. Centring the carton ensures high precision and prevents the boxes from getting stuck.

Depending on the size of the packs of chocolates, the number and orientation of the RSC boxes change and, depending on the format to be processed, they must be rotated. For this application, Schubert has designed a small special feature: an aggregate integrated in the machine rotates the already formed cartons on a separate device so that the rotation does not have to be performed by the robot during formation. This is a construction detail that allows a lighter tool to be used, which also simplifies format changeover.

The TLM machine is therefore programmed for six different formats. Five, eight, ten or twelve boxes of chocolates are inserted in each carton, sometimes vertically and sometimes horizontally, on one or two layers. The plant’s robots process up to twelve cartons per minute, preparing them for shipment. The format change of the lightline cartoning machine takes only five minutes.

For the “light” design of the entire system, the frontal warehouse has proved invaluable. By freeing up the side passage, it guarantees greater freedom of movement despite the limited space available in the production laboratory.

The first of its kind. Since its installation at Niederegger in December 2018, the lightline case packer has proven its efficiency in the field. Although this is a new project for Schubert, it does not have the typical features of the prototype (non-standardised chassis or non-unified components); it is a fully functional machine that includes the proven components of the Schubert TLM system. This enhances a particularly functional aspect of the entire Niederegger production.

As Director Kai Röblitz says, "the investment in the new Schubert machine was very cost-effective and the lightline case packer is the ideal complement to our automation processes, with the resulting increase in production capacity". Since the launch of the machine, other manufacturers have also come to these conclusions and more than 30 lightline machines are already in operation worldwide.