Rockwell Automation: multi-format packaging with one machine

CAMA and Rockwell Automation lead a high-performance packaging project for the confectionery industry.

Today's consumers have more choices than ever before. Every imaginable product and speciality, available in packaging and formats suitable for every occasion: single packs, twin packs, assorted flavours, snack-size, family packs, and jumbo formats... there is truly something for everyone! Adding to this variety are marketing activities and promotions, including seasonal products, gift packaging and volume-based offers, to name just a few. From a production standpoint, this diversity already brings a certain level of complexity. However, the real challenges emerge in secondary and tertiary packaging, where product types, volumes and box/pack/promo formats demand a wide range of packaging solutions. Moreover, many end users expect all these capabilities to be integrated into single machine.

A flexible line to meet every consumer need

This was the challenge set by Hawaiian Host Group, a North American company based in Honolulu, a leader in the confectionery industry and the world's largest producer of chocolate-covered macadamia nuts.The company needed a new machine for the primary packaging of its macadamia products – a solution that would optimise current operations while offering a modular design capable of handling future product innovations. Rising to the challenge was Cama Group, a major Italian company and a leading designer and manufacturer of packaging machines for the food industry.

The collaboration between CAMA and Rockwell Automation: a success story

The line developed by Cama Group for Hawaiian Host Group was custom-designed to address the company's specific needs. It is equipped with a Rockwell Automation control architecture that includes PLCs, drives, HMIs, switches and I/O modules. This was made possible through Rockwell Automation's Integrated Architecture®, a unified control and information system that connects industrial operations across multiple disciplines, offering one control platform, a standard design framework, interoperable and secure connectivity, visualisation tools and smart devices. Augmented reality solutions were also used for training, product and format changes and maintenance. At the heart of the machine are delta robots equipped with specially designed grippers. Using quality, shape and position data provided by an advanced laser scanner, the robots pick up chocolates from the conveyor belt and gently place them into polyethylene terephthalate (PET) trays, which arrive in parallel from a de-stacker.

Once filled, the individual trays – or pairs of trays separated by a padding sheet – are loaded into cardboard boxes, after which the lids are formed and inserted. The final result is complete boxes containing between four and 32 chocolates. The line is also capable of bulk packaging, with robots loading chocolates directly into boxes. This type of bulk packaging also serves as a fallback option in the event of line problems, helping to prevent significant downtime. At the end of the process, the boxes are x-rayed and then transported to a cartoning machine at the end of the line.

Successful results through advanced automation

The collaboration between CAMA and Rockwell Automation proved to be a powerful driver of transformation for Hawaiian Host Group. Advanced automation has not only increased efficiency – accelerating production and minimising downtime – but has also introduced considerable flexibility, thanks to a modular system designed to accommodate future product innovations. At the same time, the integration of sophisticated safety controls has raised the standards of worker protection. Process optimisation has also resulted in a significant reduction in operating costs, while automation itself has served as a key factor in ensuring high product quality.

The adoption of these innovative solutions has not only strengthened Hawaiian Host Group's market position but also opened new opportunities for long-term growth and competitiveness.