The client approached our company based on a recommendation from partners who had already collaborated with us on several automation projects for food production facilities. The primary reason for reaching out was the need to launch a new production line for cream-filled sandwich cookies, including the subsequent automated packaging of the finished products.
The enterprise faced the task of obtaining a comprehensive solution from a single supplier - covering everything from the selection of equipment to the commissioning of the production line.
Example of a finished product
Task
The client planned to set up a production line for sandwich cookies, similar to Oreo and comparable products.
Key equipment requirements:
- automatic feeding of cookies;
- application of cream filling between two cookie halves;
- quality control of the assembled products;
- automatic product counting;
- grouping of products for packaging;
- packaging into flow-pack bags;
- stable operation of the line during multi-shift production;
- minimization of manual labor and human error.
Additionally, the system needed to allow for future increases in production capacity without requiring a complete replacement of the equipment.
Solution
Following an analysis of the product, production goals, and client requirements, our specialists developed an optimal configuration for the production line.
The solution includes:
Automatic sandwich biscuit assembly machine
This unit provides:
- automatic feeding of biscuits;
- precise dosing of the cream filling;
- joining of the two biscuit halves;
- detection of missing or damaged biscuits;
- automatic product counting;
- transfer of the finished products to the packaging machine.
Automatic product grouping system
This system performs:
- grouping of a specified number of products per package;
- synchronization between the production and packaging sections of the line;
- monitoring of product flow stability.
Horizontal Flow-Pack packaging machine
This equipment ensures:
- automatic packaging of the finished products;
- high-quality longitudinal and transverse seals;
- compatibility with modern multi-layer packaging materials;
- printing of the production date and other variable information.
Project Implementation
Following the approval of the technical specifications and the manufacturing of the equipment, the production line was delivered to the client’s site.
Our specialists carried out the following:
- equipment installation;
- connection of utility systems;
- commissioning works;
- configuration of operating modes;
- training for operators and technical personnel.
Thanks to thorough preliminary project planning, the launch was completed on schedule, with no significant modifications required to the equipment design.
Results for the Client
As a result of the project, the client acquired a fully automated line for the production and packaging of sandwich cookies, which integrated several manufacturing operations into a single, cohesive technological process.
The client gained:
- automated production of cream-filled sandwich cookies;
- consistent quality of the finished product;
- reduced reliance on manual labor;
- automatic counting and grouping of products prior to packaging;
- increased production capacity;
- a reduction in production losses and defective items;
- modern flow-pack packaging for the finished products;
- the potential to further increase output volumes without requiring significant upgrades to the line;
- technical support and staff training.
