Evolution and challenges of automated packaging of chocolates

Bombones

As far as we know, chocolate or cocoa has been consumed since 1500 B.C., when ground cocoa beans were mixed with water and various spices to create a drink with an intense and extremely bitter taste, far from the hot chocolate we know today. But it was not until the 17th century, in France, that what many consider to be the most elegant and sophisticated way of consuming chocolate was created: bonbons.

In the 19th century, thanks to industrial production and the improved techniques of Belgian and Swiss chocolatiers, pralines became popular, but they never ceased to be considered a delicacy, a small morsel of pleasure. This aura of elegance and delicacy is largely due to their careful packaging.

For this reason, the automation of chocolate packaging has been a key challenge for the confectionery and chocolate industry. Wrapping and packaging are much more than just a means of preserving the product. Prior to automation, packaging chocolates was a laborious and error-prone task. Each product was placed in the tray one at a time, which was labor intensive. There was also a risk of cross-contamination during manual handling.

However, automation has made this process much more efficient. This technological advance allows companies to increase production efficiency, improve product quality and reduce operating costs, while ensuring food safety and the attractive presentation of chocolates, a crucial element in today’s marketing.

HOW DOES AUTOMATIC PACKAGING OF CHOCOLATES WORK?

Chocolates or pralines are one of the most diverse products in terms of packaging types, from simple formats in vertical bulk bags to the most sophisticated boxes. 

So how do you automate their packaging? By using specialized machines designed to handle a wide variety of sizes and shapes. These machines can perform several key functions:

  • Automatic feeding: The machines are equipped with feeding systems that transport the chocolates from the processing line to the packaging station in a continuous and constant manner.
  • Robotized packaging: Chocolate pick-and-place systems with vision-guided Delta robots are an advanced solution for chocolate packaging. These robots accurately select and position products either in trays directly from the production line or to create assortments from various product conveyors. 
  • Top-load cartoning: Top-load cartoning with Delta robots is an efficient application for placing trays of chocolates into cartons. This technology also allows precise placement of an interleaver paper.
  • Case packing: After the packaging and cartoning process, the case packing machines group the chocolate cartons into Packmaster or American type cases according to the customer’s specifications.

WHAT ARE THE CHALLENGES OF AUTOMATING CHOCOLATE PACKAGING?

One of the main challenges when loading chocolates into trays is to perform a delicate pickup that does not affect the quality of the chocolate, avoiding marks of the pickup equipment, such as suction cups, and without breaking the chocolate sheets that cover the chocolate. It is also important to take into account the brightness generated by the chocolate in the vision systems, as well as the guidance and fixing of the trays to avoid the effect of elasticity during loading. 

Another important challenge is accuracy. In this sector, it is common for chocolates, whether single varieties or assortments, to be presented in cardboard boxes with trays that have cavities specifically designed for each type of product. Precision is essential as the tolerance in the placement is minimal.

Another highlight is the speed of the picking equipment, which is the highest among the products picked with Delta robots, reaching speeds between 90 and 100 ppm, depending on the type of bonbon.

PRECISION, AN ESSENTIAL FACTOR IN PRALINE PACKAGING

To meet the challenges of the previous point, a high-precision vision system specifically designed for chocolate packaging is required. What should we consider?

  • Vision technologies: Various vision systems are used to ensure maximum accuracy and to differentiate between products. These technologies detect the position and orientation of each praline.
  • Format flexibility: Flexibility is key because the designs and shapes of chocolates are very diverse. The vision system must be able to quickly adapt to product changes.
  • Product feed adaptability: The vision system must be able to adapt to different types of supply lines, including process lines and manual loading lines, where the issues of accurate product detection are different. 
  • Intuitive user interface: It must have an easy-to-understand and easy-to-use interface for setting up new formats.
  • Integration with quality control systems: The ability to easily integrate with inspection systems independent to the robotic line is critical to ensuring that only products in optimal condition are packaged and reach the end user.

Our packaging systems are designed to ensure that each chocolate is presented in optimal condition, preserving both its quality and brightness, all at a speed that meets the production demands of the industry.

Do you want to know more about our robotic packaging systems?

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