Aargau, a chocolate company headquartered in Bux Switzerland, is a major producer of chocolate and an independent subsidiary of Migros Cooperative. Recently, it has expanded its production of a new packaging and flavor of small chocolate due to its high demand internationally. Frey, together with project partners, has implemented a space saving and effective automated packaging solution for "Compact Swiss Chocolate".

Chocolate automatic packaging production line

Most of the chocolate produced by Aargau Company is produced for the Migros Cooperative, which Aargau Company has been a member of since 1950 and sells in their retail stores. Aargau also provides services to catering enterprises, major clients, and downstream industries. In 2014, the annual output value of the company's chocolate packaging assembly line exceeded 43000 tons of chocolate, candy, semi-finished products, and chewing gum.

Chocolate automatic packaging assembly line, chocolate automatic packaging

 The constantly growing demand means that we have to increase production. The company chose a chocolate packaging assembly line system with strong capabilities, and 2013 was the year they decided to invest.

The new chocolate automated packaging assembly line has a production capacity of up to 12 tons of chocolate per hour, with 16 hour shifts per day. Due to space limitations, a compact but powerful automated packaging production line system is required. The company has decided to use four dual line LRM/2-G-S folding packaging machines, as well as buffering and conveying systems, to complete the work. The key driving factors behind choosing this device include the high speed of the packaging machine and the quality of the modular system, which require much less space than its market competitors

 1. How to implement the solution

The solution includes a feeding system that supplies materials to the packaging machine. The feeding line system usually uses a separate conveyor. This feeding method is less prone to malfunctions for small products like chocolate, and is also relatively inexpensive to maintain. Overall, it takes up less space.

 Next, enter the detection system, which automatically checks the integrity and metal contamination of each counter mold, and eliminates any problematic products. A special dual axis conveyor picking robot with a vacuum cup selects a row of chocolates from the counter mold and precisely places them on the feeder of the packaging machine. Four LRM/2-G-S folding packaging machines package up to 1050 chocolates in OPP coated film. The total capacity of these four machines, combined with the design of the entire chocolate packaging assembly line, makes effective packaging of chocolate very simple.

If the film ruptures, the product ruptures, or there are technical issues during the production process that cause the packaging machine to temporarily stop, the counter molds will be stacked at the buffer station. Once the fault is cleared, the product buffer gradually empties during normal operation of the molding unit. This means that maximum system efficiency can be ensured for customers.

Next is secondary packaging

The chocolate that comes out of the packaging system and is packaged into bags is further packaged on the conveyor system, which is called secondary packaging. The main steps of secondary packaging are to package the goods into different bag sizes, then pack them in cardboard boxes, and finally place them on pallets. This solution saves the need for temporary storage and optimizes the logistics chain.

This chocolate automatic packaging production line system has a total investment of several million euros and was put into use in late August 2014. By the end of September, it had reached full production capacity. Thanks to the high-performance system of its chocolate packaging production line, Frey Chocolate has an advantage in the increasingly competitive global environment. The management of the factory is already considering doubling its production capacity to process two tons of chocolate per hour.

The sustained cost pressure in the food industry, the impact of low-priced German products on Switzerland, high labor costs, and a strong Swiss franc all require products with excellent quality and efficient production structures. Through the upgrade and transformation of the chocolate packaging assembly line, the company and project partners have established new standards and are optimistic about the future.