Mars Netherlands asked us to develop a flexible solution that packages candies in bars of different quantities, with the requirement for faster changeover speeds—the old machines took a day and a half to accomplish this.
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When we were in the U.S. to inspect the ‘old’ machines, we found that the feeding system was insufficient to achieve the desired packaging speed.
As a result, we took the initiative to build a prototype using bowl feeders: the candies are dropped and positioned upright. This prototype was more than well-received. The process is now fully automated with sensors that count, monitor the fill level, and detect blockages.
A brush conveyor band pushes the candies forward “forcefully.” Then, a clever transfer station picks up the candies by the row and sends them to the servo-driven paper tower, where a roll of foil turns and unwinds.
This foil forms a wrapper, and a laser printer adds the expiration date (THT). While an inspection system monitors the position of the foil, the candies are inserted into the wrapper with millimeter precision. This happens about six times per second—at high speed.
Upon delivery of the machine, tests on-site revealed that the candies did not meet the previously provided specifications. As a result, the machine’s efficiency and speed were not high enough.
Through mutual understanding, trust, and support, we worked together with Mars to find a solution for the varying candy sizes. Over the next three years, we fully optimized the machine. The result: a perfectly functioning machine and a satisfied customer.
We made the difference with our approach. For example, by analyzing old machines and creating a prototype for more efficient feeding. But also by collaborating with other parties, where we acted as the system integrator, the ‘spider in the web.’
Technical highlight? How the 32 carts in the transfer station are controlled: that’s truly impressive. And the solution works even faster than specified—proof of our added value.
We achieve success together with you: side by side, engineer to engineer. This way, we help you find a reliable solution that drives the desired process improvement and results.
