One of the world’s largest producers of chocolates and biscuits required a turnkey solution for counting and packaging individually wrapped chocolate bars. The company needed an output of 150 gift boxes containing multi-flavored chocolate bar mixes. The composition of the mix must be 100 percent consistent, yet very easy to change according to predefined “recipes”.
For all recipes, the gross weight of the candy mix, as well as the net weight of the sealed final gift box, must be checked to adhere to the company’s quality assurance process.
The chocolate manufacturer placed the entire project in Cremer’s hands, including the full integration of a food-grade cartoning machine that could operate at the required speed and deliver the same level of quality, efficiency and reliability.
It has become common practice for many industries to provide the manufacturer with a detailed URS (User Requirement Specification). This aided Cremer in designing the counting and packaging system not only according to CE machine building regulations and the highest safety standards, but also according to very specific customer design preferences regarding routine cleaning and maintenance.
To meet the high production capacities needed, the company installed 12 of Cremer’s HQI 6100 counting machines. The HQI 6100 is a six-channel product counter typically used for apportioning various wrapped confectionery products.
This model features four vibrating V-shaped plates for fast transport and efficient product separation and singulation. Six separate product detection channels “scan” and count each individual product with 100% accuracy, whether the product has a flow wrap, twist wrap or foil wrap. Three vertically stacked “memory flap units” with silent servo motors collect the counted products and dispense them in preset quantities into the passing buckets via an alternating discharge chute.
The standard HQ-model has a maximum output of 170 discharges per minute, a rapidity necessary to fill the chocolate manufacturer’s gift boxes at a constant requested speed of 150 boxes per minute.
The 12 counters were placed over a double track bucket conveyor. To produce 150 boxes per minute in a 24/7 manufacturing environment demands seamless integration between the counting system and the vertical cartoning machine, which is manufactured by Senzani and largely customized to Cremer specifications.
Six two-in-one product supply systems are used for delivering 12 different types of chocolate bars to the counting machines. Each of the 12 HQI 6100 counters processes one specific flavor and dispenses a preset quantity of its product into the passing containers of the double-track bucket conveyor.
When the last counting machine releases its product count into the bucket, it contains a mix of 12 different flavors with a predefined number of each flavor. The composition of the mix is fully customizable and can be easily changed according to different box formats or shifting marketing trends.
The conveyor buckets are emptied into a series of timing hoppers that check the weight of each mix and release multiple mixes simultaneously into the vertical cartoner’s high-speed rotary turret. The chosen cartoning machine can handle multiple box formats with distinctive shapes, which also was an essential aspect of this project. A secondary checkweigher and an innovative box orientation system prepare the correctly filled and closed gift boxes ready for palletization.
With the addition of its 12 new Cremer counting machines, the chocolate manufacturer has seen improved efficiency with increased production outputs and 100% accurate counts, ensuring quality for its customers and avoiding costly wastage/overcounts.
HQI 6100 product counting machine
The HQI 6100 is a 6-channel product counting machine that is typically used for counting all sorts of wrapped confectionery products and dispensing them in preset quantities into a bucket conveyor.
Four vibrating V-shaped plates are used for fast product transport and efficient product separation and singulation. Six separate infrared product detection channels “scan” and count each individual product with 100% accuracy, regardless if the product has a flow wrap, twist wrap or foil wrap. Three vertically stacked “memory flap units” with silent servo motors collect the counted products and dispense them in preset quantities into the passing buckets via an alternating discharge chute.
The HQI 6100 counter, either as a stand-alone machine or as part of a mix line, offers 100% accuracy, high speed and great versatility for all sorts of confectionery products, and more.
Typical applications for the HQI 6100 counter are;
- foil wrapped chocolates
- twist wrapped fudge
- flow wrapped candy bars
- fruit gums
- candy sachets
- seasoning and bouillon cubes
- wrapped lollipops
- beverage capsules
We are always happy to help. Do you have any questions regarding possible counting solutions? Would you like some advice regarding your production facility? Do not hesitate to contact us.