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THE CUSTOMER MAG A ZINE FROM ME YPACK

IssUe 1 | 2012

MoRocco – A DeseRt PeARL MeyPAcK RePoRts on MoRocco, tHe MAGHReBIAn KInGDoM In noRtHWest AFRIcA

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A little grain – in a starring role

Anuga FoodTec 2012

Growth Market

Meypack supplies a combined endpackaging machine to Reismühle Brunnen

Meypack presents a new tray/lid case packer in cologne

With its tailor-made solutions, Meypack has established itself in the food industry


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e D I to R I A L 3

Dear Readers,

Peter Böckenholt, Managing Partner of Meypack Verpackungssystemtechnik GmbH

Around 50 years ago, Meypack got its start in the machine manufacturing business. At that time, the company’s focus was solely on the beverage and canning industries. The machine portfolio and technical innovations were developed to suit these industries. It was a question of packing bottles, jars and cans as fast and economically as possible. However, soon the market started to exhibit much greater product diversity. Other product shapes, formations and materials came on the scene. Product diversification – with the goal of providing consumers with the largest variety of products to meet their individual needs – is the new catch phrase. In this context, it has paid off for Meypack that it has long been in the enviable position of not only being able to build solid standard machines but also to plan, design and build customised solutions to meet the unique needs of its diverse customers. Consequently, it was a logical step to incorporate and cultivate companies from the food industry into its customer segment. In addition to the beverage industry, we are increasingly serving more customers from the food industry, coming from the most varied areas of this segment. Our machines are particularly well-suited for customers with a broad product spectrum. Developing expertise for the food industry was an extremely extensive task that we approached with a great deal of dedication and continue to do so to this day. The success achieved thus far motivates us even more to continue along this chosen path. Today, Meypack is almost equally active in the beverage and canning industries as well as in the food industry – worldwide. We are eager to take on further challenging tasks, which we will master and execute. In this current issue of the kompackt, you can read about some of the highlights of our recent activities. And we will be presenting first-rate ideas for the food industry at Meypack’s trade fair stand at this year’s Anuga FoodTec in Cologne. Come visit us and we would be very pleased to discuss them with you. I hope you enjoy the current issue of the kompackt and that it gives you some new food for thought.

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4 contents

26 CSM Deutschland Meypack installs two VP 451’s to pack blocks and slabs of margarine

30 Growth market – the food industry

22 Unilever Hungary

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Meypack rises to the sophisticated challenges of this market segment

Cosumar Meypack supplies three additional packaging machines plus a PK 110 palletiser to this Moroccan sugar cone producer

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Success stories: At Reismühle Brunnen (RMB), products are fed into the machine via a paddle chain and are then pushed out as a row of products

IMPRINT

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Success stories: With more than 50 years of tradition under its belt, Café Liégeois is an internationally well-known quality coffee roaster, remaining true to its love of coffee

Publisher: Meypack Verpackungssystemtechnik GmbH Industriestraße 3 D-48301 Nottuln-Appelhülsen Tel.:  +49 (0) 2509 - 940 Fax:  +49 (0) 2509 - 948190 info@meypack.de www.meypack.de

At its production facility in Röszke, Hungary, the fifth Meypack machine goes into operation

Managing Partner: Peter Böckenholt

Engineering: Meypack develops a new paddle chain, which guarantees reliable transport of the products into the packaging machine

Conception, Compilation, Design: FBKB – Agentur für Kommunikation Linus-Pauling-Weg 8 D-48155 Münster Tel.:  +49 (0) 251 - 9811990 Fax:  +49 (0) 251 - 98119910 post@fbkb.com www.fbkb.com

Photos/Illustrations: Meypack, Cosumar, Reismühle Brunnen, Café Liégeois, Unilever Hungary, CSM Deutschland, Koelnmesse, istockphoto.com, dreamstime.com Print-run: 3,000 copies Frequency: 2 x per year

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contents 5

31 Last but not least

3 Editorial

A total of six new employees are starting work at Meypack in early 2012

6 Morocco – a desert pearl

Meypack reports on Morocco, the Maghrebian Kingdom in northwest Africa

12 A sweet cone – but not the frozen variety Meypack delivers three more packaging machines as well as a palletiser to Morocco 14 A little grain – in a starring role Meypack supplies a combined VP 451 K SW 60 D end-packaging machine

to Reismühle Brunnen (RMB)

18 For the love of coffee The Belgian company Café Liégeois once again places its trust in Meypack technology 2 0 Multifunctional and ingenious Meypack’s new paddle chain guarantees reliable product transport

– even at very high running speeds

22 It’s in the bag Meypack delivers the fifth machine to Unilever Hungary 26 The baker’s favourite ingredient … CSM Deutschland receives two Meypack end-packaging machines 2 8 Anuga FoodTec 2012 Meypack presents a new tray/lid case packer 3 0 Food industry Meypack reports on highly complex applications and the extremely diversified product

range in the sophisticated food market and how it rises to these challenges

31 Last but not least

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QR-Codes lso can now a d n be fou in ckt the kompa

Copyright: © 2012 Meypack Verpackungssystemtechnik GmbH

For questions about distribution or orders: Tel.:  +49 (0) 2509 - 940 kompackt@meypack.de

Any reproduction subject to prior approval. The contents do not necessarily reflect the opinion of the publisher in every instance.

This issue of the kompackt magazine can be viewed online at www.meypack.de

carbon neutral natureOffice.com | DE-260-892426

print production

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6 PeoPLe & PL Aces

Morocco – a desert pearl In Arabic, Morocco means al-Mamlaka al-Maghribīya, “the Western Kingdom.” It is situated in northwest Africa and borders on both the Mediterranean as well as on the Atlantic. the word Maghreb originally meant “the West.” the name Morocco was derived from the name of the former capital Marrakesh in the 16th century.

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PeoPLe & PL Aces 7

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ven though the land area is rela- extensive plateau also referred to as the inner meseta tively small in comparison to other or the high plateau of Marrakesh. African countries, it does boast In the South and East, the meseta is surrounded by diverse topographical features. The Mediterranean the distinctive High and Middle Atlas mountain Coast is predominantly characterised by steep cliffs as ranges. Functioning as an important climatic division, well as many capes and bays. In the West, the moun- the mountain ranges separate the Atlantic/Medtainous coastal section stretches in a crescent shape to iterranean Morocco from that part of the country the northwest tip of Africa in the direction of Europe. influenced by the Sahara. The highest mountain in In contrast, the Atlantic Coast is a flat, smooth, counter- North Africa is Jbel Toubkal, measuring 4,167 metres. balancing coastline with strong sand movement, South of this, peripheral desert landscape stretches making it unsuitable for harbours. Stretching inland out, encompassing the Tafilat Basin and the Draa there are wide coastal expanses, such as the Sebou Valley. In Western Sahara along a wide coastal plain, Gorge near Kenitra, as well as Casablanca’s expan- dune-covered sandstone plateaus – which are dissive coastal meseta, or plateau. Further inland, the sected by dried up river beds known as wadis – rise elevation climbs to around 450 metres above sea level up to a height of 350 metres and are also classed as to the central section of the Moroccan Meseta, an part of the Sahara.

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8 PeoPLe & PL Aces

climatic extremes The Moroccan climate transitions from the Mediterranean influenced Northwest of the country to the Saharan-continental South and Southeast. The northwestern section experiences hot, dry summers. Temperatures during the mild, rainy winters average around 12 °C, although the rainfall tapers off towards the South. Moving into the interior, the moderate influence of the ocean drops off considerably, giving way to a characteristically continental climate

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in the central meseta and in the Atlas Mountains: In Marrakesh summer temperatures can reach 45 °C while winter temperatures can hover around freezing, even accompanied by snow in the mountain regions. South of the Atlas Mountains, the peripheral Sahara region is subject to an extremely hot, dry desert climate. There is very irregular precipitation, making cultivation only possible in oases with irrigation. During the summer months the occasional sirocco wind blows through – hot and dust-filled coming from the Sahara.

A nation of Berbers and nomads? Berbers and Arabs comprise the population of Morocco. Approximately 80 % of the inhabitants are Berbers who are predominantly settled farmers; only a minority still live as nomads or seminomads in remote areas of the Middle Atlas Mountains or on the high plateaus in the eastern part of the country. The largest Berber ethnic groups are the Chleuh (language: Taschelhit), the Beraber (language: Tamazight) and the Rifkabylen (language: Tarifit). The Haratin, the Moroccan Jews as well as the residents of European descent represent the most important ethnic minorities in the country. It can generally be said that the Berbers tend to be more rural while the Arabs are primarily city dwellers. The only large Moroccan city with a Berber majority is Marrakesh. On the whole, the population density in Morocco is very uneven. Two-thirds of the inhabitants live on approximately onetenth of the land area in the Northwest or the West. Areas of


PeoPLe & PL Aces 9

The city of Casablanca with a view of the Hassan II Mosque, one of the largest mosques in the world

urban concentration are found in the coastal regions in the North and Northwest as well as in the Sebou lowlands. The official language throughout the country is Arabic. A wide array of Berber languages is spoken by Moroccans of Berber ancestry. French is used throughout the entire country as the language of trade and education. Spanish is also spoken in northern Morocco, in Western Sahara and in Sidi Ifni. Morocco is a member of the United Nations, the Arab League and the World Trade Organisation (WTO).

casablanca – the most important metropolis in the country The city’s name is derived from Spanish and means “white house.” The Arabian name is “Dar el Beida.” Casablanca lies south of the capital Rabat, directly on the Atlantic Coast. It is the most important trade and industrial centre in Morocco, has the largest harbour in North Africa and is the largest city in Morocco with approximately 3.5 million inhabitants. When the outlying urban areas are included, Greater Casablanca

is home to around 4 million residents and is the most densely populated city in the country. Historical records make reference to the Berber settlement of Anfa in the 8th century, its foundation walls serving as the base on which the current city was built. In the 18th century, it was re-settled by Arabs under the name Dar el Beida. Spanish merchants also moved there and named the city Casablanca. At the end of the 19th century, many Europeans moved to Casablanca. The nearby phosphate deposits made the city the most important trading centre; it was built into an economic centre, where numerous colonial buildings and villas were erected. Casablanca maintained its position as an economic hub after the colonial period and is the most important city in the country today. The fish canning industry and nearly half of the remaining Moroccan industry have also set up shop there.

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10 P e o P L e & P L A c e s The Draa Valley in Morocco, a peripheral desert landscape of the Sahara

was created amidst the backdrop of the Second World War and has become a film classic that still enjoys great popularity today. One quote from Casablanca, Bogart’s famous line “Here’s looking at you, kid!” is one of the most famous in film-making history. In 2002, the American Film Institute chose “Casablanca” as the best US love story of all time and in 2007, it was selected the third best US film in history. Over 60 % of the entire Moroccan export business is handled in Casablanca’s harbour. Many of the country’s important companies, such as Cosumar, have their headquarters there.

tea and sugar – the Maghrebian tea culture

The Moroccan national drink is peppermint tea, otherwise known as thé à la menthe or whisky marocain, a combination of Chinese green tea with fresh mint “Here’s looking at you, kid!” (known as “nana” in Arabic) that is mostly served with a lot of sugar. Casablanca – it isn’t only the largest city in Morocco The art of tea preparation is a ritualised form of but also the setting of the famous Hollywood film tea drinking in Maghrebian countries as well as classic “Casablanca” from 1942, starring Humphrey in northwest African countries such as Morocco, Bogart and Ingrid Bergman. The film “Casablanca” Mauritania, Algeria and Tunisia as well as with the Tuareg people. It is a ritual with an important communicative function and is an integral part of social interaction.

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P e o P L e & P L A c e s 11

Lighthouse at Cape Spartel, the most northwestern point in Africa at the entrance to the Strait of Gibraltar

To prepare the beverage, green tea is placed in a pot and cooked for a number of minutes. Thereafter, the tea is strained into another pot, a large amount of sugar – preferably from a sugar cone – is added, and the mixture is then boiled. During the process of re-boiling, the sugar molecules hydrolyse, splitting into glucose and fructose, altering the flavour of the tea and making it sweeter. Fresh mint leaves are often added, either during the boiling process in the pot or to the glasses when the tea is being served. In cafés in Morocco, green tea is served in small pots which the customer uses to pour into the glass and over the mint leaves and chunks of white sugar. The sugar needed for this tea preparation, as well as for other purposes, is produced by the local company Cosumar in Morocco and packed with Meypack end-packaging machines.

coUntRy PRoFILe

Kingdom of Morocco Official language: Arabic Capital city: Rabat Form of government: constitutional monarchy Head of state: King Mohammed VI Area: 446,550 km² Population: 32,360,471 (october 2011) Population density: 72 people per km² Currency: Moroccan dirham Independence: March/April 1956 Time zone: Utc

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12 s U c c e s s s to R I e s

A sweet cone – but not the frozen variety the sugar cone is solidly anchored in Moroccan tradition and plays a central role in the daily lives of Moroccans. It is not simply a food product, but is also a symbol for family, hospitality and religion. the Moroccan company cosumar produces this crystallised product, in addition to other varieties of sugar.

I

n 1929, the company Cosumar was founded in Casablanca by the “Société Nouvelle des Raffineries de Sucre de Saint Louis de Marseille.” Over the years, it has grown into a state-run company with an annual turnover of nearly 5.8 billion Moroccan dirhams in 2010 (around 520 million Euros). The company employs approximately 2,500 people. In addition to the sugar refinery in Casablanca, Cosumar also owns five sugar beet processing facilities in Doukkala, Gharb, Loukkos, Tadla and Moulouya and two sugar cane processing facilities in Gharb. The company also produces sugar cubes and granulated sugar in addition to the traditional sugar cones.

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s U c c e s s s to R I e s 13

cooperation for more than ten years Back in 2000, Meypack developed a machine to pack sugar cones by positioning them on pads and then wrapping the bundle in shrink film for the production facility in Sidi Bennour. The 2 kg sugar cones are positioned in groups of 6 onto a pad. Two additional cones are then inserted upside down into the formation of 6. The group of 8 is then wrapped in film and shrink-wrapped to create a stable bundle.

2011, a Meypack PK 110 palletiser was installed at the facility in Casablanca as part of a pilot project. With a palletising output of two layers per minute, this single palletiser is able to process the bundles emerging from two shrink-wrapping systems. As soon as the new production hall has been completed in Sidi Bennour, this palletiser will be installed there. The factory in Casablanca will then get a Meypack palletiser with a higher capacity of four layers per minute. Eventually, this palletiser will palletise bundles of sugar cones emerging from a total of four shrinkwrappers.

The Moroccan company Cosumar, founded in 1929 by the “Société Nouvelle des Raffineries de Sucre de Saint Louis de Marseille” produces many sugar products. One of them is the sugar cone, a product solidly anchored in Moroccan tradition. The company employs around 2,500 staff members and has its headquarters in Casablanca.

the sugar cone – a product with a history and a tradition

Berber woman at a tea ceremony with frish peppermint tea and sugar cone

A sugar cone has a rounded upper tip and is made entirely of sugar. While the shape has become very rare on a worldwide scale today, during the 19th and 20th century it was the most common form of sugar sold due to the production methods of the times. The sugar cone is extremely hard and must be broken into smaller pieces in order to be used for most purposes.

In 2008, two further packaging machines of the same type were ordered for the newly built facility in Casablanca. Both machines were delivered in Meypack CleanDesign execution. In 2010, three more machines followed: two for the facility in Sidi Bennour and one machine for the Suta production facility Ouled Ayad, a sugar company acquired by Cosumar in 2005.

The sugar cone has a permanent place in Moroccan tradition. Associated with the important events in the life of a Moroccan, it is not only served during traditional tea ceremonies but also during other events such as pilgrimages, weddings and births. The sugar is broken into smaller pieces with a special, often decoratively adorned sugar hammer, or occasionally with tongs.

Meypack Representative Morocco: Walter Mertz Hamburg Bureau au Maroc 10, Rue Iles Caraibes 20050 Casablanca (Ain Diab) Morocco Tel. +212 (0) 522-797929 Fax +212 (0) 522-797654 klaus.mertz11@gmail.com

From the pad to the pallet

Contact person: Klaus Mertz

Palletising the bundles of sugar cones had been carried out manually at all of the facilities. In May

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14 s U c c e s s s to R I e s

A little grain – in a starring role For more than half of the world’s population, rice is the main staple food. there are more than 120,000 types of rice worldwide. the swiss company Reismühle Brunnen (RMB) has been importing rice products from around the world for more than 50 years.

fair & good The Swiss company Reismühle Brunnen (RMB) imports rice products from around the world. The company was founded as a joint stock company in 1956. Since 2004, RMB has been a division of the Coop Group, with a distinctive identity of its own at its Brunnen location.

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A

fter undergoing special monitoring to determine if the incoming raw rice is of the agreed quality and free from pests or mould, the husks are removed in a rice mill. What remains is the whole, natural grain consisting of the endosperm, germ and the encompassing bran. This stage is referred to as hulled rice or brown rice. Some of this natural rice or whole grain rice makes it onto the store shelves. Further milling removes the bran and the germ from the hulled rice. In this form, the rice is referred to as white rice or milled rice. The raw rice remaining after milling is smoothed through a friction polishing process. This is carried out either dry or with water by forcing the grains against each other, with the resulting fric-

tion serving to polish and whiten the rice. To prevent the enormous loss of vitamins and minerals during processing, the raw rice is first soaked in water and then treated with hot steam, causing the nutrients that are being released to diffuse into the endosperm. This process creates parboiled rice (from partially boiled), which retains approximately 80 % of the vitamins and minerals contained in the natural, whole grain brown rice. The entire production process is accompanied by a number of cleaning steps. These include magnetic separators to remove any metal bits that might have made their way into the batch, sieves to sort out left over husks, straw, or other grains of cereal, as well as


s U c c e s s s to R I e s 15

de-stoners to sort out any foreign particles the size of a rice grain, such as little stones or weed seeds. Lastly, a light sensor carries out optical monitoring to identify and sort out dark grains or those of the wrong colour.

switzerland’s no. 1 rice importer Meypack Representative Switzerland:

The Swiss company Reismühle Brunnen (RMB) imports rice products from around the world. The company was founded as a joint stock company in 1956. Since 2004, RMB has been a division of the Coop Group, with a distinctive identity of its own at its Brunnen location. RMB employs a workforce of 18. The company’s location in Brunnen, on the banks of Lake Lucerne, is very central and excellent in logistical terms. RMB imports rice from all over the world, mostly using ecologically responsible forms of transport such by ship or rail. The rice processing is carried out by modern equipment that ensures gentle product handling. Working in two shifts, RMB achieves a production capacity of approximately 12,000 tonnes of rice, of which 10,000 tonnes are convenience products. Through gentle processing, a high yield of about 82 % is generated. Sorting and milling the rice generates by-products amounting to about 18 % of weight, which are transformed into high-quality animal fodder.

Chromos AG Niederhaslistrasse 12 8157 Dielsdorf Switzerland Tel. +41 (0) 44-8555000 Fax +41 (0) 44-8555110 rolf.knaus@chromos.ch Contact person: Rolf Knaus

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16 s U c c e s s s to R I e s

“In my opinion, Meypack is the ideal choice in the area of secondary packaging. The critical factors for The product range produced us were the compact in Brunnen covers about 40 types of rice with more machine design, format than 300 forms of packaging in a variety of shapes and flexibility and the tech- designs. nically sophisticated execution.” Diligence and reliability – Gerhard Marty, Head of Production

also during end-packaging In autumn 2010, RMB invested in a combined Meypack VP 451 K SW 60 D packaging machine that was commissioned in May 2011. The machine packs bags and folding boxes of rice in a total of 14 formations into trays with or without film, or alternatively in wrap-around cases. The machine packs rice in bags ranging from 0.5 kg to 2 kg and in folding boxes from 0.25 kg to 1 kg. The bags and folding boxes first enter the case section of the Meypack machine in continuous motion in single file with the short side leading;

they are then brought into a standing position in the paddle chain. The desired formation is created at the end of the infeed conveyor, where the products are pushed over row by row. Simultaneously, a flat cardboard blank is removed from the blank magazine and positioned directly underneath the grouping station. The product formation and the blank are guided together into the lateral folding aids of the lowering station. During this step, the blank is folded very tightly around the product formation, then glued and pressed. In the final film section, trays can also be wrapped in film and shrunk. If film is not desired, the trays just pass through this section. The machine output is dependent upon the type of packaging and the upstream machine.

the clinchers: Machine design and format flexibility The determining factors for the purchase of this Meypack machine were in particular the compact and open design of the machine as well as

All in a row: Products are fed in via a paddle chain then pushed out row by row

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s U c c e s s s to R I e s 17

Basmati Rice Salad Serves 4

Ingredients

red pepper 1 yellow pepper 1 te green peas, cooked al den 200 g Basmati rice 300 g black olives, pitted 8 cayenne pepper mixed leaf lettuce sted in the oven) sesame seeds (lightly toa

Sauce: wine vinegar cider, white wine or red 3 TB vegetable stock 2 TB soy sauce 1 TB Dijon mustard 1 Tsp olive oil, extra virgin 5 TB pper freshly ground black pe herbed salt

meters that can be automatically changed. Given the diversity of products that RMB packs, it was important to find a highly flexible solution to enable not only fast but also simple format changeovers that can be carried out by RMB’s operating staff. All bundled up: Lowering a product formation onto a wrap-around blank in 4 x 3 formation

the technical features with respect to the format changeovers and energy efficiency. The machine is not only compact but also constructed in Meypack CleanDesign execution. Thanks to the open design, cleaning the machine with compressed air as well as mechanically is extremely easy. Abstaining from the use of water – something that is an absolute necessity when processing rice – poses no problem either. Given that hygiene is also an important criterion for RMB and stringent food and hygiene regulations must be strictly adhered to, this proved to be another plus point for Meypack.

Preparation

ds and dice the halves. ove the stalk and the see rem , ers pp pe o tw e added. Boil for five Halve th th one teaspoon of salt wi ter wa l m 0 90 in the rice frequently Boil the rice tes over low heat. Check inu m 15 for r me sim minutes, and then t enough. e pepper to taste. to see whether it is sof e sauce and add cayenn th to e ric and es oliv e seeds on top. Add the peppers, peas, and sprinkle the sesam uce lett f lea ed x i m e on th d in the oven first. Arrange the rice salad if they are lightly roaste r tie tas n eve be ll wi The sesame seeds

Sustainability and energy efficiency are very important topics at Reismühle – solar energy has been in use since 2011, a reason why the engineering department places a high priority on servo motors. The advantageous energy balance of the Meypack machine was another aspect that gave the nod to the Meypack solution.

Another decision criterion that spoke for Meypack were the fast modular change systems with para-

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18 s U c c e s s s to R I e s

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offee is Germany’s favourite beverage: Germans drink around 150 litres per year – and with that more than water or beer. That is the equivalent of three to four cups a day. In 2008, a total of approximately 400,000 tons of roasted coffee and around 12,200 tons of instant coffee were sold throughout Germany, corresponding to 519,000 tons of green coffee. The highest coffee consumption in the world is in Finland, where 11.5 kilograms or 1,300 cups of coffee are consumed per person per year. The Belgians follow with 9.5 kilograms of coffee per person, with the Norwegians, Danes and Swedes close behind at 9 kilograms. In Switzerland, Germany and the Netherlands, per capita consumption comes in at a little more than 6 kilograms.

For the love of coffee

café Liégeois – a company combining tradition with passion The creation of Café Liégeois can be attributed to Charles Liégeois’s passion for coffee. The Belgian family business was founded in 1955 and is run today by Charles’s two sons, Michel and Benoît, employing The Belgian family business was around 100 people. Today, with more than 50 years founded in 1955 and is run today by of tradition under its belt, Café Liégeois is an internaCharles Liégeois’s two sons, Michel tionally well-known quality coffee roaster, remaining and Benoît, employing around 100 true to its love of coffee. people. Today, with more than 50 years of tradition under its belt, Café Liégeois is an internationally well�known well known quality coffee roaster, remaining true to its love of coffee. The headquarters of Café Liégeois are located in the Belgian town of Battice in the region of Liège.

A perfect fit: Placing the pre-formed, inner-lying lid into the tray inside the lowering station

Roasting and sales of coffee account for 60 % of Café Liégeois’s business activities. To round out its repertoire, it also packages sugar and milk. Parallel to this, the company provides logistic and customer services for the installation and maintenance of coffee and espresso machines for professional clients and private

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coffee – it is lifestyle, passion, indulgence, tradition. coffee is the cosy cappuccino in a café or at home, but it is also the “latte to go” for on the road. coffee is undisputedly the favourite beverage of Germans and one of the most popular beverages in europe.


s U c c e s s s to R I e s 19

“We can act, so we should act!” customers, in addition to delivering a wide range of products such as snacks, beverages, cleaning products and dishes that are required by business clients and public institutions.

Meypack packaging machines in triplicate

At the Belgian production facility in Battice, three Meypack maCafé Liégeois is headquarchines are in operation packing tered in the Belgian town of pouches of coffee pads for Café Battice in the region of Liège. Liégeois. Two of the machines Administration, production are VP 451 K wrap-around facilities and the warehouse case packers that pack pouches of 18 are located there, covering an The origins of and of 36 pads area of around 9,000 m². coffee can be traced in 5 x 2 and 5 x 3 formations into to the Ethiopian Mano Mano – Hand in Hand wrap-around cases. region of Kaffa. A new Meypack VP 452 packs the pouches In the highlands Café Liégeois is a coffee roaster. Thus, it goes of coffee pads in trays with lids. The there, the plant without saying that the company is in contact with 4-sided lid is inserted into the tray and species caffea arabica countries in Middle and South America, Africa secured with adhesive. It is also poshas its origins. It is and Asia. sible for this machine to pack in wrapthe mother of all of Working in close cooperation with Terre Solidaire around cases. Pouches of 18 and 36 today’s various coffee and the Max Havelaar brand, Café Liégeois devel- pads are packed in 5 x 1 and 5 x 2 forplants worldwide. oped the Fair Trade product line Mano Mano and mations. The pouches with 48 pads brought it onto the market. The name stands for the or respectively 56 pads are packed in will to work with the farmers in Chiapas in South- 5 x 2 formations and only in wrap-around cases. east Mexico hand in hand. While the two Meypack VP 451 K’s can pack 25 Meypack Representative Belgium: pouches per minute, the VP 452 processes 35 Bipack bvba The objective of Mano Mano is to guarantee the pouches per minute. Rollegemsestraat 13 8510 Bellegem (Kortrijk) producers a minimum price regardless of the Belgium current market price, according to the princi- To be able to meet the growing demands posed Tel. +32 (0) 56-373545 ples of Fair Trade. This guarantees that the pro- by today’s supermarkets, the third machine was Fax +32 (0) 56-373546 ducers earn a correct and constant minimum designed to be able to pack in wrap-around cases info@bipack.be with Easy-Opening perforations as well as in trays income. By doing this, Café Liégeois makes a clear with lids. Contact person: Christian Holcomb statement and even reinvests € 0.10 into the province of Chiapas for every package of Chiapas Coffee Pads sold in the supermarket.

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20 e n G I n e e R I n G

Multifunctional and ingenious: Meypack’s new paddle chain Growing demands for greater robustness and flexibility were decisive in the development of the new Meypack paddle chain, which guarantees reliable transport of the products into the packaging machine – even at very high running speeds of up to 300 products per minute.

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e n gi n e e ri n g 21

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odern packaging machines are characterised on the one hand by increasingly high cycling rates and on the other by the largest possible flexibility and the easiest handling when it comes to format changeovers. These are demands placed on the packaging industry by today’s international corporations. Meypack’s new paddle chain was developed to fulfill the increased demands for ever higher capacities. It is a consistent further development of the proven chain system.

Paddle chain with product specific product cycling via a star wheel system

Optimal curve shape for fast and safe transport The mechanical form of the paddle chain has been completely overhauled and adapted to ensure that the products enter the paddle chain at the optimal infeed angle. In the new system, the products always enter lying flat and are then brought into the desired position, in which they are then packed.

Side view of a dual cluster paddle chain for high-speed applications, either for pouches or folding boxes

The infeed angle of the paddle chain is optimally set according to the product to be packaged. This ensures fast and reliable erection of the product in the paddle chain. Each paddle in the new paddle chain is individually controlled, enabling a strong and precisely guided paddle situation when the products are being pushed out of the paddle chain.

summary Use of the new paddle chain in both the VP 400 Series and the VP 500 Series Fast and reliable erection of the accumulated products thanks to the optimised chain curve Robust and precise paddle situation when the products are being pushed out of the paddle chain, thanks to individually controlled paddles Innovative change system for fast and easy format changeovers Emptying the paddle chain by pushing the products out, or alter natively by using either a gripper system or a suction system

Emptying the paddle chain can be achieved by pushing the products out, or alternatively by using either a gripper system or a suction system.

Not simply a quick change artist A particular highlight of the new paddle chain is the possibility for a fast and easy change. The innovative change system encompasses the entire paddle chain, making it possible to exchange the chain in one fell swoop. The new paddle chain is used in the packaging machines of the VP 400 Series and the VP 500 Series. This paddle chain is especially well-suited for light, narrow products like pouch packages, such as soup pouches with sealed edges. It is also well-suited for products like folding boxes, stand-up pouches, bags or shaped containers.

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22 s U c c e s s s to R I e s

It’s in the bag In the Hungarian village of Röszke, located south of Budapest near the serbian border, Unilever Hungary uses Meypack VP 453 case packers to pack pouches – an up-to-date, sophisticated technical end-packaging solution.

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s U c c e s s s to R I e s 23

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n Röszke, Unilever Hungary produces food products for a total of 17 European countries, predominantly for Hungary, Austria, Poland and the Czech Republic. The new Meypack VP 453 case packer is now the fifth Meypack machine for Unilever Hungary. Three of the machines pack Doypacks, 4-sealededge pouches as well as double compartment (powder + baking bag) pouches in display trays with lids partially inserted and partially applied to the outside of the tray. The machine has two parallel infeed conveyors, enabling the trays to be filled in an alternating fashion from two sides. The products enter the packaging machine lying flat and are each individually turned by a turning unit in such a way that the bottom edge leads and the “face” of the pouch faces upward. The individual pouches are then cycled into a stacking shaft that can receive up to seven products on each latch. The latches open at lightning speed when the stacks of pouches are being transferred onto a metal plate below, which is lowered in a controlled manner. A cross pusher pushes the stack of products into a compartment in a rack located in front. This process is repeated until the desired number of products has been reached, whereby the rack is

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24 s U c c e s s s to R I e s

lowered one level at a time along with each product stack. The rack has a total of five compartments and can yield a maximum number of 35 products per tray. Once the rack has been filled and then lowered, a second cross pusher simultaneously transfers all product stacks to a pivoting stacking shaft. The pivoting shaft also has individual compartments that are, however, flexible. Once all of product stacks have been received, they are pressed together to create a tight formation that can be guided safely and precisely. The pivoting stacking shaft pivots 90 ° so that the products are then standing upright, close together side by side. The stacking shaft then moves upward where the formation is pushed by a cross pusher out of the shaft and placed onto a tray blank. The tray blank and product formation are lowered into the cycling chain, forming the tray. The tray filled with products is glued and pressed and then transported into the pre-formed lid. The lid is generally positioned on the outside of the tray. However, on the long side of the tray, the lid is partially inserted into the tray and secured with adhesive points to prevent slippage. The lid securing points serve as a modern packaging solution that gives the packaging stability and the possibility of it being quickly and easily opened at the point of sale. The lid is affixed with two glue points but is easy to open manually. The machine can process diverse formations that are dependent upon the respective sizes of the pouches. The pouch width and length play a role as does the thickness of the pouch, which varies

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In the Hungarian village of RĂśszke, Unilever Hungary produces food products for a total of 17 European countries, predominantly for Hungary, Austria, Poland and the Czech Republic. The production facility in RĂśszke is located south of Budapest, near the Serbian border.


s U c c e s s s to R I e s 25

Step by step: Product flow through the Meypack VP 453 case packer

depending upon the content. In addition, double chamber pouches can also be processed. The changeover to different tray formats takes place nearly tool-free. Only the product-specific parts need to be changed.

Unilever – successful with well-known brands from the food industry As one of the largest producers of food products, Unilever produces and sells food that makes healthy eating taste good, easy to achieve and affordable. Throughout the entire production process, beginning with the procurement of raw materials, continuing through the production process on to the delivery of the final product, Unilever pays close attention to maintaining strict quality and hygienic standards. One of Unilever’s most well-known brands in the food area is Knorr. Knorr products are among the world’s most successful consumer goods. Already back in the 50’s and 60’s of the last century, “Knorr” became synonymous for quick and delicious soups and a trailblazer in the area of convenience foods. Today, Knorr products are simply permanent fixtures in the kitchens of millions of consumers – serving as valuable helpers in such forms as mixes for meals or salad dressings, as soups, sauces or quick ready meals. For a majority of its product portfolio, Knorr relies on pouch packaging, and not just in Hungary.

Pouch packaging – practical but fragile and a real challenge for the end-packaging industry The challenge of packing pouches lies in the “instability” of the product – especially in the case of double chamber pouches. The packaging material used exhibits a low degree of stability, which manifests itself in pouches without defined, recurring dimensions, making processing more difficult. In contrast to tins or jars, for example, various types of contents can have a strong impact on the reaction and dimensions of the primary pouch packaging.

A special form of pouch packaging that is particularly popular with consumers is the sealed pouch. This pouch is not only easy to handle and space saving but is also a hygienically safe form of food packaging. In particular, powdery products such as instant soups or liquid products like dressings are packed safely and in a spacesaving form in these pouches. The sealed pouches are available in a variety of forms: with or without stand-up bottoms as well as the option of a re-sealable closure. The most common variations of the sealed pouches are the flat pouch, the stand-up pouch, the double chamber pouch and the bottom gusseted pouch. In line with Unilever’s Compass strategy for sustainability, which includes doubling its business while halving the environmental footprint of its products, this system solution has definite advantages. These include the utilisation of servo motors instead of pneumatics, with an added bonus that this optimised servo controller solution reduces electricity consumption. Furthermore, continuous, positively controlled movement of the products through the system allows little opportunity for the powdery product content to settle and create bulges in the pouches. As a result, this packaging solution guarantees higher capacity utilisation of the trays of around 10 to 15 %, reducing the need for corrugated cardboard and improving product transport efficiency, thereby contributing to lower CO2 emissions.

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26 s U c c e s s s to R I e s

The baker’s favourite ingredient … csM Deutschland is the leading supplier of products for artisan and industrial producers as well as industrial consumers of baked goods in the German market. the product range includes, among many other things, special margarines that needed to have particularly “soft” handling in the end-packaging.

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pecial margarines and special fats are among the most important raw materials in the production of fine baked goods. Without these ingredients it would be impossible to produce such a wide array of baked goods in terms of taste, appearance and functionality. During today’s production processes for baked goods, the plant oils and fats used have been created to contain precisely calculated proportions of combined fats, which serve to fulfill the needs of the special margarine used later in the production process. Through the composition and mixing ratios of different fats and oils as well as their derivatives, different consistencies, melting points and creaminess can be attained. The oils and fats used include canola/rapeseed oil, sunflower oil, palm oil and coconut fat. For the baking industry, the melting point is of great importance. Furthermore, the fatty acids play an important role in both the consistency and firmness of the fat. One differentiates essentially between cream margarine for fillings and batters, baking margarine – otherwise known as Danish pastry margarine – as well as puff-pastry margarine. All three types of margarine are available in different levels of quality and there are consequently “Gold Brands,” which

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s U c c e s s s to R I e s 27

Margarine was developed by the French chemist Mège-Mouriès in 1869 as a response to a reward offered by Napoleon III for a cheap alternative to butter. Mège-Mouriès created margarine out of a mixture of beef tallow and skim milk.

are of a particularly high quality due to the optimal composition of raw materials and ingredients that remain highly stabile during the baking process.

csM – a leader when it comes to special margarines For the baked goods industry, special margarines are portioned into blocks and slabs, and then packed. In the northern German city of Delmenhorst, CSM Deutschland produces many products under the brand MeisterMarken, including its “Gold” puff-pastry margarine in slab form for the production of laminated pastry dough such as puff-pastry dough. Thanks to its high melting point, puff-pastry margarine is

Precise: Controlled product cross pusher with integrated product centering on the loading plate before stacking

particularly malleable. For the production of Danish pastry dough using machines, CSM offers slabs of special Danish pastry margarine that are extremely easy to use. In addition to slabs of margarine, the company also produces blocks of margarine. Blocks of margarine, such as Meister Goldzieh, also come as puff-pastry margarine and are thus optimal for producing flaky puff-pastry. In contrast, the product Grand Patissier Creme is perfect to use when making creams and dough. This margarine guarantees a high degree of air absorption, which in turn enables the pastry to expand to a large volume.

Blocks and slabs safely packed CSM Deutschland is the leading

Meypack installed two VP 451 wrap-around case supplier of products for artisan and industrial producers as well packers to pack blocks and slabs of margarine as industrial consumers of baked into wrap-around cases at CSM Deutschland. The goods in the German market. The machines have been designed to ensure gentle product range includes, among many handling of the products during processing, given other things, special margarines such as cream margarines for fillings and that the blocks and slabs of margarine are not yet batters, baking margarine completely firm after they have left the extrusion otherwise known as Danish unit. Furthermore, the product transport is extremepastry margarine - as well as puff�pastry margarine. ly gentle in order to prevent the flaps of the wrapping material (aluminium, HDPE, PP, PE or paper) from opening or creasing. The margarine blocks are packed in two layers while the margarine slabs are packed in layers of five. The second machine can pack wrap-around cases with flush-lying side flaps and overlapping side flaps. The machines are equipped with turning stations that turn the product formations either lengthwise or crosswise after they have exited the grouping station – depending upon the desired product direction within the case. Both machines were delivered in stainless steel and CleanDesign executions – aspects that were very important to the customer because product hygiene receives a very high priority at CSM.

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28 e X H I B I t I o n s

Anuga FoodTec 2012: Meypack pres new tray/lid case packer At the Anuga Foodtec in cologne, Meypack exhibits a VP 453 case packer – built in stainless steel in accordance to the cleanDesign construction Principle – to process plastic containers of butter by packing them in trays with lids. the Anuga Foodtec is the event where the food industry gets together.

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he Anuga FoodTec, international trade fair for food and beverage technology, is set to be very visionary and future-oriented this year. Trends and innovations for the coming years from both food and beverage producers as well as from packaging specialists are the focus of the world’s most important trade fair for food and beverage technology, running from March 27th to 30th, 2012 in Cologne.

With this packaging machine designed for a sophisticated dairy-food application, Meypack presents an array of ground-breaking concepts – concepts that will provide interesting stimuli and perspectives for other customers and branches.

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e X H I B I t I o n s 29

Hygiene and gentle product handling during packaging – the most important factors in the production process The Meypack VP 453 on exhibit was built entirely of stainless steel according to the CleanDesign Construction Principle. Optimal accessibility, easy and thorough cleaning as well as the machine’s high level of flexibility were convincing arguments for the customer to order two identical tray/lid case packers from Meypack. These were all important criteria, given that the stacking stations will be located in wet areas of production while the packaging machines will be in dry production areas.

sents Both machines pack rectangular plastic containers of 250 g, 500 g and 1,000 g in trays with lids. The unique lid is inserted into the short side of the tray while the longer sides of the lid are glued to the outside of the tray. The plastic containers have a slightly conical shape and are sealed with a plastic lid on top. One challenge of the project was to transport the containers without pressure and to pack them in a gentle way for two important reasons: On the one hand, the lids can easily come off if there is even the flightest bit of pressure exerted; on the other hand, the product is still in a fluid state at the time of packaging and can thus easily swash onto the inside of the lid. The plastic containers enter the stacking station in two lanes. Inside the stacking station, one row of products per lane is created, which is then lowered into the stacking shaft. The procedure is repeated until the desired number of layers has been reached. From the stacking shaft, the complete multi-layered rows of products are pushed – alternately from the left and the right sides – onto an intermediate table. This is repeated until the desired number of product rows has been created. The subsequent grouping is carried out by a servo motorised finger grouping system and a

servo motorised cross pusher. The cross pusher stands out due to its extremely gentle product handling, in which only the very bottom containers in the formation are touched in a few places and at no time is there any pressure exerted on the lid – a special feature of this machine.

one of the machines live in action at Meypack’s trade fair stand The machine on display features a number of highlights that are of particular importance for the food industry. In addition to the optimal accessibility, the CleanDesign execution and the gentle product handling technology, the machine is extremely flexible and can also be used to create wrap-around cases with external top flaps. The format changes are also fast and easy to manage. As a result, a format changeover can be completed within a maximum of 30 minutes by just one operator. This isn’t the first project for this customer: Over the past years, three VP 451 case packers in CleanDesign execution have been commissioned and a further stainless steel VP 531 machine for a high-speed application is currently in the works.

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30 At W o R K

The food industry – the growth segment for Meypack Highly complex applications, extremely diversified products and the highest requirements for hygiene in the production process – those are just some of the key points that make the food market particularly challenging and sophisticated. It is in this market segment that Meypack has established itself as a customised machine manufacturer offering tailor-made solutions for its customers.

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hen a company is particu- “The objective was to supplement the portfolio larly successful in a market, of machine applications in a logical and sensible an area or a product cate- manner to secure our long term stable growth. For gory, this is usually reflected by continuous growth this reason, we have been consistently expanding our over a long period of time. And this growth is what product and service range to meet the needs of the Meypack has recorded over years in the discerning food industry as well and developing packaging applifood segment. For decades, Meypack was one of the cations for the food and non-food areas since 2005,” leading German packaging machine manufacturers explains Klaus M. Vogel, Director of Export Sales and for the beverage and canning industries in the end- Marketing at Meypack. packaging area and it is well established and well-known in this market segment. And still The challenges that present themselves when one enters today, machine systems are a new market were characterised in our case by new product manufacturing processes. As a result, not only the line capacities but also the shapes and specific characteristics of the products to be packed, the materials used, local conditions such as temperature and humidity in the production facilities or difficult to define product tolerances all pose real challenges to be mastered. Furthermore, the strict hygienic regulations in food production facilities as being built for the beverage industry well as the corresponding sophisand sold to domestic and international customers. ticated project specifications, the extremely specific Parallel to this, activity in the food market has been cleaning processes and the demands for flexibly developing very positively since 2005. Meypack has designed machines were topics that the Meypack developed a foothold in this sophisticated market planners and engineers successfully addressed. segment, proven by a large number of successful projects that Meypack can already reflect back upon and Today, Meypack is almost equally active in the customers who have ordered machines with Meypack beverage and canning industries as in the food to expand existing facilities or to start up new produc- and non-food industries – and in the meantime tion locations. worldwide.

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L A s t B U t n ot L e A s t 31

QR Codes – now also in the kompackt they’re everywhere, everyone’s talking about them – these QR codes. But what are they actually and how do they work? QR stands for quick response. With the help of these codes, smartphones and PDAs (personal digital assistants) that are equipped with cameras can call up, save or further process information contained in these codes. QR Codes are different from the previous 2D-barcodes because they can save both vertical and horizontal information and therefore can contain a greater quantity of data. A QR Code can contain information such as internet addresses, telephone numbers, text messages, links, texts or electronic name cards. How do they work? The user requires a QR Code reader app on his or her smartphone or PDA, which

can be installed for free. The app is then activated and scans the QR Code. Within a few seconds, the QR Code is analysed and the coded link, or respectively the desired website, is opened by a browser. Why does Meypack use QR Codes in the kompackt? Meypack utilises QR Codes primarily to save links to websites. With the help of the QR Codes, the links guide the user to special sites on the Meypack website that have additional pertinent information (machine information, service topics as well as videos and photo galleries) or also links to external websites that can be easily called up by the user. By incor-

porating QR Codes, Meypack combines offline and online content in a simple way. Furthermore, scanning a QR Code is much easier than typing in a complex internet address. In the upcoming issues of Meypack’s kompackt, QR Codes will be easy to find with the icon. The kompackt wishes all its readers lots of enjoyment when trying them out.

Committed to personnel development A total of six new employees are starting work at Meypack in early 2012 – four of them are former apprentices from a diverse range of apprenticeship programs After completing her apprenticeship, Mareike Dresemann will be working as an in-house electronics technician for electrical installations on customised machines, while Lukas Hengemühle will be sharing responsibilities for installing and commissioning electrical machines on-site for customers in Germany and abroad. As a trained mechatronics technician, Florian König commissions palletisers and customised machines both in-house

and on-site at the customer. Another graduate is Marius Wies, who is responsible for the assembly of the entire machine at Meypack’s production facility in Nottuln as well as for the installation of the machine on-site at the customer. Since February 2012, Florian Springeneer has been working as a mechanical engineer designing Meypack’s packaging machines in the engineering department. He holds a Bachelor of Engineering degree. Com-

petent support will also be provided by Ilhan Caner, who has a degree in electrical engineering. He will build the control systems for the case packers, install them and then conduct testing on the machines. The kompackt wishes all of the new colleagues a successful start at Meypack.

Dates 2012 March 27th to 30th, 2012

Anuga FoodTec 2012

Cologne, Germany

September 25th to 27th, 2012

FachPack 2012

Nuremberg, Germany

Hall 6, Stand B60/C61

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Meypack Verpackungssystemtechnik GmbH Industriestraße 3 · D-48301 Nottuln-Appelhülsen · Tel.: +49 (0) 2509 - 940 · Fax: +49 (0) 2509 - 948190 · info@meypack.de www.meypack.de

kompackt - the customer magazine from meypack  

kompackt - the customer magazine from meypack

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