Food Safety
search
cart
facebook twitter linkedin
  • Sign In
  • Create Account
  • Sign Out
  • My Account
Food Safety
  • NEWS
    • Latest News
    • White Papers
  • PRODUCTS
  • TOPICS
    • Contamination Control
    • Food Types
    • Management
    • Process Control
    • Regulatory
    • Sanitation
    • Supply Chain
    • Testing and Analysis
  • PODCAST
  • EXCLUSIVES
    • Food Safety Five Newsreel
    • eBooks
    • FSM Distinguished Service Award
    • Interactive Product Spotlights
    • Videos
  • BUYER'S GUIDE
  • MORE
    • ENEWSLETTER >
      • Archive Issues
      • Subscribe to eNews
    • Store
    • Sponsor Insights
  • WEBINARS
  • FOOD SAFETY SUMMIT
  • EMAG
    • eMagazine
    • Archive Issues
    • Editorial Advisory Board
    • Contact
    • Advertise
  • SIGN UP!

Packaging perspectives on bar production

By Douglas Peckenpaugh
Bosch Bar Line
May 5, 2017

Equipment technology suited to bar production continues to grow in terms of streamlined efficiencies for greater throughput and hygienic design. Josua Schwab, product manager, Bosch Packaging Technology, Stuttgart, Germany, provides some top-line insights for consideration.

 

Douglas J. Peckenpaugh: Which trends are impacting bar production and packaging?

Josua SchwabJosua Schwab: Chocolate products are a real winner with consumers in the U.S., accounting for around a third of all confectionery sales on average per year. There is, however, increasing demand among consumers for a healthier option—muesli or nut bars, and “free from” products. This makes the bar market very attractive to manufacturers, but also highly competitive. This competition, coupled with rising prices for ingredients, such as cocoa, puts producers under significant cost pressures. It is not generally considered possible to influence commodity prices directly, so manufacturers are turning to leaner and more-efficient processes to increase overall equipment effectiveness (OEE). Here, the crucial elements for success are a well-planned, continuous product flow, with safe and gentle bar handling and an efficient cleaning concept.

 

DJP: How can manufacturers get the most out of their bar packaging systems?

JS: The average figure for OEE in the packaging machine and granulation plant sector is just 24 percent, according to survey data from the VDMA (German Mechanical Engineering Industry Association). With an optimum OEE of 100 percent, 63 percent are lost to availability, 11 percent to performance and 2 percent to quality.

A seamlessly integrated system instantly offers manufacturers significant efficiency improvements in the areas of availability and performance. A consistent product flow is given, when all system components are perfectly matched and in constant communication with one another. In addition, gentle product handling together with quality control and 3D monitoring reliably prevent product jams or downtime caused by breakages or defective bars at all stages of the packaging process. A robust design, which uses standardized parts and uncomplicated maintenance, guarantees good availability of the system even in a multi-shift operation.

The feeding system is very important for an efficient packaging process. It represents the smart logistics, ensuring a consistent product flow throughout the entire process. The products are received directly from the manufacturing process and prepared for distribution to the packaging leg. The Bosch distribution stations are extremely precise, with a row performance that is currently unmatched in the industry. The result: gently handled, perfectly rotated, aligned and indexed bars. Products can be held briefly on waiting belts or stored temporarily on storage belts, even in gondola storage, to bridge breakdowns and to synchronize the packaging process with the overall production.

Control sensors check the length, width and height of the products, while metal detectors ensure that products are free from metal objects and ejected from the packaging process. After the preparation process, the feeding system passes the products to the flow wrapper at top speed and at the correct cycle rate.

The new, intelligent transport system “Sigpack FIT” (Feeding Intelligent Transport) from Bosch harmonizes the product flow with full automation, ensuring a consistently high speed, which is additionally supported by flexible format change at the push of a button.

 

DJP: What role does hygienic design play in packaging equipment effectiveness?

JS: The hygienic design of a system directly influences the cleaning time requirement for a system. The lower the accumulation of contaminants and the easier the machines are to clean, the shorter the downtimes for cleaning. Availability and quality are also linked with system hygiene. For sticky bars and/or nut products, in particular, the level of contamination is very high and cleaning the plant is very important but also very time-consuming. According to the UK Food Standards Agency (FSA), the number of food recalls increased by 78 percent in 2015 compared to 2014. This is an unsettling development that we are looking to counter with our hygienic system design. The aim is to keep downtime for cleaning as short as possible, to prevent cross-contamination between product changes and to avoid waste. Two factors are crucial here: gentle product handling and system design.

Ideally, the transport of the product is smooth and generates little friction. This causes minimal wear to the belts and lengthens the time between cleaning. Rounded side guides reduce breakage and avoid accumulations of residues in the system, also minimizing product waste. Another important factor is avoiding having stationary parts above the process belt. This ensures that the bars cannot become contaminated by dust and other residues. The operator can inspect the process at any time thanks to observation windows, transparent casings, and enhanced accessibility. In addition to using high-quality materials, such as stainless steel and FDA-compliant belt material, the ability to remove components quickly for thorough cleaning also improves OEE. Simple and quick belt changes and roller removals, together with belt scrapers, support hygienic design and reduce downtime for cleaning.

 

DJP: What options are available to manufacturers for fast and efficient cleaning?

JS: Every product—whether it’s a chocolate bar or a sticky muesli bar—has its own particular cleaning requirements. For example, in the case of very sticky products, manufacturers can make use of a belt washing unit for continuous belt cleaning during the process. This reduces downtime, as intense cleaning is required less frequently. With a belt washing unit, production can take place continuously for up to 30 days with two 12-hour shifts.

If nut bars are being produced, for example, all parts that come into contact with the product, such as belts, rollers, scrapers or side guides, need to be changed completely and thoroughly cleaned. This is very time-consuming. To quickly resume to production without the risk of allergens, Bosch offers a second format set with a format parts carriage. This allows one set to be thoroughly cleaned while the second set is being used for production. In a four-leg system, four operators need just two hours to changeover the format parts and clean the entire system.

This article was originally posted on www.snackandbakery.com.

This article was originally posted on www.snackandbakery.com.
KEYWORDS: hygienic design

Share This Story

Looking for a reprint of this article?
From high-res PDFs to custom plaques, order your copy today!

My photo2016200

Douglas J. Peckenpaugh is Group Editorial Director of Snack, Bakery, Cannabis, Meat, and Candy for BNP Media. He has over two decades of publishing experience following the food industry from farm to fork, covering agriculture, ingredient processing, CPG and foodservice R&D, retail and restaurant menu trends, and retail grocery branding. He is a member of the Research Chefs Association and the International Foodservice Editorial Council. Doug studied Professional and Creative Writing at Purdue University.

Recommended Content

JOIN TODAY
to unlock your recommendations.

Already have an account? Sign In

  • people holding baby chicks

    Serovar Differences Matter: Utility of Deep Serotyping in Broiler Production and Processing

    This article discusses the significance of Salmonella in...
    Testing & Analysis
    By: Nikki Shariat Ph.D.
  • woman washing hands

    Building a Culture of Hygiene in the Food Processing Plant

    Everyone entering a food processing facility needs to...
    Personal Hygiene/Handwashing
    By: Richard F. Stier, M.S.
  • graphical representation of earth over dirt

    Climate Change and Emerging Risks to Food Safety: Building Climate Resilience

    This article examines the multifaceted threats to food...
    Contamination Control
    By: Maria Cristina Tirado Ph.D., D.V.M. and Shamini Albert Raj M.A.
Manage My Account
  • eMagazine Subscription
  • Subscribe to eNewsletter
  • Manage My Preferences
  • Website Registration
  • Subscription Customer Service

More Videos

Sponsored Content

Sponsored Content is a special paid section where industry companies provide high quality, objective, non-commercial content around topics of interest to the Food Safety Magazine audience. All Sponsored Content is supplied by the advertising company and any opinions expressed in this article are those of the author and not necessarily reflect the views of Food Safety Magazine or its parent company, BNP Media. Interested in participating in our Sponsored Content section? Contact your local rep!

close
  • Two men standing in a produce storage facility having a discussion.
    Sponsored byOrkin Commercial

    Staying Compliant With FSMA

  • Deli Salads
    Sponsored byCorbion

    How Food Safety is Becoming the Ultimate Differentiator in Refrigerated and Prepared Foods

Popular Stories

FoodSafetyMattersFinal-900x550-(002).jpg

Ep. 195. Dr. Christopher Daubert: The Value of a Food Science Education

Students returning their lunch trays in a cafeteria

California Bill Would Remove Ultra-Processed Foods from School Lunches

Image of baby being fed infant formula

HHS Budget Request Beats Familiar Drum

Events

June 26, 2025

How to Design and Conduct Challenge Studies for Safer Products and Longer Shelf Life

Live: June 26, 2025 at 2:00 pm EDT: During this webinar, attendees will learn how to conduct challenge studies for microbial spoilage and pathogen growth, including the common challenges encountered, laboratory selection, and use of predictive models.

May 11, 2026

The Food Safety Summit

Stay informed on the latest food safety trends, innovations, emerging challenges, and expert analysis. Leave the Summit with actionable insights ready to drive measurable improvements in your organization. Do not miss this opportunity to learn from experts about contamination control, food safety culture, regulations, sanitation, supply chain traceability, and so much more.

View All

Products

Global Food Safety Microbial Interventions and Molecular Advancements

Global Food Safety Microbial Interventions and Molecular Advancements

See More Products
Environmental Monitoring Excellence eBook

Related Articles

  • Douglas J. Peckenpaugh

    Legal perspectives on the state of CBD

    See More
  • State of the Industry 2018 Overview: Perspectives from top bakery industry leadership

    State of the Industry 2018 Overview: Perspectives from top bakery industry leadership

    See More
  • Pack Expo Las Vegas

    PACK EXPO review: Inside the expanding world of packaging at PACK EXPO Las Vegas

    See More
×

Never miss the latest news and trends driving the food safety industry

eNewsletter | Website | eMagazine

JOIN TODAY!
  • RESOURCES
    • Advertise
    • Contact Us
    • Directories
    • Store
    • Want More
  • SIGN UP TODAY
    • Create Account
    • eMagazine
    • eNewsletter
    • Customer Service
    • Manage Preferences
  • SERVICES
    • Marketing Services
    • Reprints
    • Market Research
    • List Rental
    • Survey/Respondent Access
  • STAY CONNECTED
    • LinkedIn
    • Facebook
    • Instagram
    • X (Twitter)
  • PRIVACY
    • PRIVACY POLICY
    • TERMS & CONDITIONS
    • DO NOT SELL MY PERSONAL INFORMATION
    • PRIVACY REQUEST
    • ACCESSIBILITY

Copyright ©2025. All Rights Reserved BNP Media.

Design, CMS, Hosting & Web Development :: ePublishing