The industrial production of snacks represents a constant challenge for food companies. Between the growing demand for packaged products and the need to maintain high quality and safety standards, designing efficient production lines becomes a fundamental strategic element.
One of the most effective solutions for optimizing production flow and reducing waste is represented by storage systems, which play a crucial role in managing micro-stops and ensuring operational continuity.
The Production Cycle of Snacks: From Line to Packaging
The production process of snacks is divided into multiple phases, each contributing to the creation of a final product ready for the market. It starts with primary packaging, where snacks are individually wrapped in flowpack, then moves to secondary packaging (cardboard trays) and overwrapping (multiple flowpack). Finally, the products are packed in corrugated cardboard boxes for shipping.
This articulated chain requires perfect coordination between different machines and careful management of operational pauses. Inadequate control of micro-stops can generate significant production inefficiencies. Without a storage system, excess products risk creating congestion along the line, forcing upstream machines to interrupt production.
This scenario is particularly critical for baked products, where production continuity is not only essential for maintaining the quality of the final result but also for ensuring safety. Products in transit through the oven must proceed without interruption: a belt stoppage inside the oven would not only cause burning and consequent loss of the product being processed but could create an even more serious risk. In large industrial ovens, where significant volumes of product are in transit, a blockage could lead to overheating and, in extreme conditions, even fire development, putting at risk not only production but also the safety of the entire facility.
Storage Systems: The Optimal Solution
Companies have two main strategies available to manage micro-stops: investing in standby machines or integrating storage systems.
Although the first option might seem more intuitive, it involves high costs both in terms of initial investment and maintenance. Storage systems, instead, represent a more versatile and economical solution.
A storage system consists of a conveyor belt with input and output devices, designed to manage excess products in a fluid and organized way. The versatility of these systems allows them to adapt to the specific needs of the production line, optimizing flow without interruptions. Moreover, many storage systems utilize vertical space thanks to spiral designs, reducing floor space and improving plant organization.
Heliflex: An Advanced Solution for Complex Lines
Among storage systems, Heliflex stands out as a solution specifically designed for complex packaging lines like those for snacks. Heliflex uses a unique chain, wound in a spiral around synchronized drums. This design allows for continuous or discontinuous product accumulation, with a capacity that ideally varies between 200 and 500 meters, ensuring optimal use of available space.
One of Heliflex’s main advantages is zero-pressure management, which ensures the integrity of products and packaging. This feature is fundamental for snacks, where damaged packaging could compromise freshness and aesthetic appearance. Furthermore, the system allows products to be returned to the line at any time without having to empty the entire buffer, offering unparalleled operational flexibility.
In an articulated production line like that of snacks, Heliflex is typically positioned after the tray packer, to manage micro-stops of downstream machines, such as overwrapping, case packing, and palletizing.
In more advanced lines, it’s possible to integrate additional storage systems to improve production efficiency. An example is the multi-tier buffer, positioned between the process line and flowpack machines for primary packaging. This system is designed to manage the flow of not-yet-packaged products, handling them in their “naked” form and ensuring fluid and organized management.
Tailored Solutions for More Efficient Production Lines: The Importance of Strategic Choice
Each production line has specific needs, determined by factors such as product type, line speed, and downstream machine capacity. For this reason, the choice of storage system must be carefully planned, considering not only current needs but also potential future developments.
Heliflex represents an example of how technological innovation can respond to these needs, offering a versatile and scalable solution. However, its integration requires careful planning and thorough evaluation of the production layout. For example, using spiral buffers not only optimizes space but also improves overall line efficiency, reducing downtime and minimizing waste.
With MH Material Handling, you can count on tailored solutions to optimize every aspect of your production line. Thanks to our exclusive service, the MH Solution Scan, we can thoroughly analyze your packaging lines, identifying critical areas and proposing the best alternatives to increase productivity.
Don’t let inefficiencies compromise your competitiveness: contact us today and discover how we can help you transform your production into a cutting-edge system, ready for future challenges.
Co-Owner M.H. Material Handling Spa – For almost twenty years he has been working in the field of product handling during packaging, supporting companies that want to optimize the entire line. Always up-to-date on industry innovations and new materials, he makes his experience available to clients with the ultimate goal of eliminating interruptions and inefficiencies in the packaging process. Voracious reader, overnight writer and content creator.
