March 29, 2023
Thanks to the unique NOTIS packaging line, a confectionery factory automates swiss roll production and will significantly reduce packaging costs. The line adapts to the production conveyor speed at up to 100 rolls per minute: it automatically receives the product and forms impeccable packages.
On 26 March, successful trials of a new packaging line for a confectionery factory located near Saint Petersburg were conducted in the NOTIS assembly shop.
Fully automatic swiss roll packaging line
The main challenges of automating packaging at confectionery factories lie in two stages:
- transferring the product flow from the production line conveyor to the packaging machines,
- feeding the fragile product piece by piece onto the packaging machine conveyor in time with the film sealing cycle.
We are proud to possess the necessary technologies for automating confectionery product packaging and to have developed them ourselves. Our products have already demonstrated their effectiveness, and dozens of NOTIS packaging systems are successfully performing their functions at chocolate factories across Russia. More detailed information, including videos, can be found on our dedicated page covering confectionery packaging equipment.
The Swiss Roll Packaging Project
100 pieces per minute
Illustration: confectionery factory for swiss rolls
Several months ago, representatives of a chocolate factory located near Saint Petersburg approached us. They needed a packaging complex developed for delicate and large-profile swiss rolls. Unlike chocolates, this product requires additional protection against deformation. Before packaging, each roll must be placed on a sturdy cardboard tray. The customer's request was simple:
The production line on the conveyor outputs rows of fresh swiss rolls. We need a packaging line that automatically:
- moves each roll onto a tray as gently as possible, leaving no damage or marks,
- pre-forms trays from a large roll of cardboard,
- wraps the rolls in film with neat, clean seams so that every package looks impeccable,
- the packaging line must fully adapt to the output rate of the confectionery line.
When discussing a project's requirements, we always find out whether a significant increase in output must be planned for. To keep retrofitting costs down, some units of the line can be designed in a particular way. In this case, no output increase was required due to the limitations of the confectionery line: 100 rolls per minute is the maximum.
NOTIS Packaging Solution for Swiss Rolls
Unique confectionery production technologies in Russia
Forming the stream
Packaging line conveyor
We take care to preserve the appearance and quality of the product at every stage of packaging. NOTIS specialists long ago worked out how to gently pick up a confectionery product from the production line and pass it to the packaging machine conveyor. The delicate surface of sponge rolls is easily damaged if the product is pushed, as ordinary solutions do. The video above shows the optimal NOTIS approach. The product moves from the process conveyor onto ours, where rows are aligned and deftly flipped onto a perpendicular conveyor. The result is a sequential row of product directed towards the packaging machine.
Alignment conveyor system
At the final stage the flow of confectionery products enters an alignment system of mini-conveyors. Here, under the watch of multiple sensors, the rolls advance towards one another thanks to the different speeds of the small conveyors. As a result, gaps between the rolls disappear — without using push paddles. The system then feeds the product piece by piece onto the packaging machine conveyor. This smart pacing system is the pride of NOTIS engineers. We have been developing the solution for 10 years and have implemented it in numerous packaging lines. The stability of its operation allows us to export packaging lines to different corners of the world. For example, in Dubai a NOTIS line has been packaging Vienna waffles for 5 years.
Cardboard roll for tray forming
Before packaging, each swiss roll must be placed on a cardboard tray, otherwise the roll's bulky shape may collapse during transport. A special packaging unit forms trays from a large roll of cardboard strip. The machine cuts a sheet to the length of the roll, scores it, folds it and feeds it out. Thanks to the two-storey design of the packaging line, the product is gently placed onto an individual tray.
Synchronisation of All Processes
NOTIS know-how
Packaging machine
Synchronising the speed of all processes is the most fascinating part of the task for the company's software engineers. Thousands of line operating scenarios must be anticipated and the system's response worked out.
- If the confectionery roll line falters — the packaging line stops.
- The output of the confectionery line may vary slightly in real time: not strictly 100 rolls per minute but 98–102. Even if output drops sharply by half, the packaging line will adapt on its own.
- If the packaging line stops in an emergency, the receiving conveyor will reverse, and product will be moved to a dedicated container.
- What if a roll on the conveyor is positioned differently from the specification? The line will try to correct it, and if it cannot — it will divert that roll off the line.
- What if the film roll runs out? The second film roll will automatically engage. The same applies to the cardboard trays.
- If the machine fails to feed a tray, the roll will also be diverted from the line. The same is true in reverse: no roll — no package.
The reliability of the NOTIS packaging line lies in its accounting for many influencing situations and the predictability of its behaviour. The "smart" system knows the status of every unit, all processes are synchronised, and hypothetical emergency situations cause the operator no concern whatsoever.
Personal Service and Easy Maintenance
Training, commissioning and warranty
To ensure the commissioning of the line goes as smoothly as possible, we invited the customer's engineer to spend a couple of days at our factory for training during the assembly-floor trials. Then, once the packaging equipment is delivered to the customer's plant, our specialist will fly out. He will carry out supervisor installation, commissioning, staff training, and will monitor the line's operation during the first few days.
We guarantee that our packaging line will operate without interruption, but if needed, the team is ready to assist by phone, video call or on-site visit. Our service department offers free consultations throughout the entire service life of the packaging machines. NOTIS customers know that we are prepared to supply the necessary spare parts even if the equipment was manufactured more than 20 years ago. We are proud that we never leave a customer with an unresolved problem.
Why Choose NOTIS Equipment
Accountability, expertise, price
The confectionery enterprise near Saint Petersburg has chosen NOTIS equipment for the third time, as the previous two lines for chocolate slabs and chocolate-coated biscuits proved stable and highly effective.
Our company is an expert in developing complex automated lines for confectionery enterprises. We create unique packaging equipment in-house, from laser cutting, metal bending and machining to the manufacture of metal and plastic components. The NOTIS design bureau handles the engineering of the complete line, individual units, electronics, and control interfaces. Every stage of production is under our control, which allows us to guarantee high product quality.
In the confectionery industry we compete with the strongest players in the packaging machinery market from Western countries and Turkey, matching them in engineering depth and reliability. The arguments in our favour are: ease of interaction, availability of spare parts, and the overall cost of the equipment.
We understand that purchasing packaging equipment can be a significant investment, and financial organisations are often indispensable. NOTIS has many years of experience working with various leasing companies. They trust us as reliable and responsible suppliers, and therefore offer our customers favourable deal terms. The swiss roll packaging line project, for example, was financed through Baltic Leasing.
Impeccable Packaging
The result of the line's work
The NOTIS packaging line forms an impeccable package that preserves the freshness, appearance and quality of the swiss roll. Neat seams, no creasing, a uniform shape — all this allows the product to stand out favourably on store shelves. Thanks to the sturdy tray and tight wrap, rolls can be stacked on top of each other with no concern for their appearance.
Conclusion
We are proud to have handled one of the most technically complex projects of the past year. For our engineers this became an excellent challenge that let them showcase their talents in solving interesting problems.
Our packaging complex accounts for every conceivable scenario in the product flow and dynamically adjusts to the product feed rate. Although our solution is highly sophisticated technologically, it is easy to operate and does all the work on its own.
If you need a solution for packaging rolls at your confectionery factory, contact us. We are ready to offer you our experience and reliability to handle any packaging task. Ask your questions by email market@notis.ru, by phone: +7 383 292-60-06 or by messenger +7-913-916-60-06 WhatsApp
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