Baking & Snack - July 2018 - 112

VARIETY PACKS

6- or 8-packs today, and then in 2 months do a holiday
pack to add an extra product or even a coupon for promotion," said Dennis Gunnell, vice-president, sales and
marketing, Formost Fuji.
"The challenge is that you don't always know what
the extra piece is going to be, so you have to anticipate
something that you can't predict," Mr. Gunnell said.
Having multiple items in one bag or box is already complicated, so the trick for bakers is to not only forecast
those adjustments but also know how much they are
willing to invest in terms of dollars and efficiency. "The
more adaptability you build, the more efficiency you're
likely to lose," he added.
This can be especially challenging for operators such
as co-packers, and the key is to keep open lines of communication with customers, equipment vendors and
internal departments such as R&D or marketing. Look
at the big picture and understand what makes the most
sense and where the worthy investment is.

While most of the specific
technology advances are
happening in the robotics
realm, primary packaging
that feeds into those units
can streamline the process
while saving a bit of space.
For BPA, the three tenets of the company are innovation, partnership and flexibility, which is an
integral part of the company's equipment design.
"Innovation and flexibility are how we approach the
industry when evaluating a footprint by offering flexible solutions that can accommodate tough layouts
and innovating new solutions that focus on space savings," Mr. Campbell said.

Labor relations
Traditionally, variety packs have been a manual operation. However, the manufacturing talent pool is dwindling, and that's leaving bakers and snack producers in
a lurch when it comes to the old way of doing things.
More than ever, they're relying on automation to fill that
packaging gap.
"The largest advancement has been the ability to feed
product from bulk and then pick and place into a car-

112 Baking & Snack July 2018 / www.bakingandsnack.com

ton," Mr. Campbell said, noting that BPA's feeders allow
for just this style of automation.
Bill Kehrli, vice-president, sales and marketing,
Cavanna Packaging Group, also noted the labor issue
with manually assembling variety packs. "There was typically a team of people to package the products - granola bars, cookies, crackers - and manually place them
into secondary packaging that could be a carton, bag or
flowwrapper," he said.
By using scanners and vision systems that can ensure
accurate counts and proper varieties, Cavanna's automation can help supplement the workers that are becoming increasingly unavailable. "Through barcode scanners, operators can make sure the flavors match up with
what's supposed to be running," Mr. Kehrli said. "These
are safe check measures to help operators avoid human
errors."
The company also offers robotics solutions that fill in
when there's a lack of human workforce.
On the horizon, collaborative robots are providing assistance that doesn't totally eliminate people but
can help with challenges such as ergonomics and other
strain-related physical issues. Collaborative robots also
take up a smaller footprint than large industrial robotic
systems. While this innovation is still on the fringe for
the baking industry, many bakers and packaging suppliers are keeping it on the radar.

Space saving
Oftentimes space constraints go hand-in-hand at the
end of the line, and this can't be truer for variety packs.
This is a big reason why many food manufactures think
hard before keeping this part of the process in house as
opposed to hiring a co-packer.
"This is a challenge, especially with older plants that
are already maxed out, when someone says, 'We want to
put a package out there with three varieties, but we need
to do it in the same space with the same people,' " Mr.
Gunnell said. "They have to look at the space they have
available and figure out how to shoehorn it in."
Cavanna's Twin Slim system also helps consolidate
the footprint in this area. "It can fit in the space of one
wrapping system and provide twice the speed and half
the labor," Mr. Kehrli said. "It's basically two machines
in one."
While most of the specific technology advances are
happening in the robotics realm, primary packaging that
feeds into those units can streamline the process while
saving a bit of space. Formost Fuji works closely in feeding the robotics and collation machines. "We can build
conveyors that are thinner or a design that will match up
with the robotics or mechanical collating features," Mr.
Gunnell said.


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Baking & Snack - July 2018

Table of Contents for the Digital Edition of Baking & Snack - July 2018

Baking & Snack - July 2018
Contents
Contents
Editorial - Unexpected perks of the job
Newsfront - FDA fiber decision pleases ABA, industry partners
Mondelez focusing on local
Paxiom opens fifth Xperience Center
News - Private label becoming greater force in snack market
BEMA announces 2018-19 executive committee officers
In Memoriam
People/In Brief
iba - HOME AWAY FROM HOME
iba 2018: US Pavilion Booth Previews
iba 2018: International Booth Previews
Canyon Bakehouse - REUNITED!
The art of product development
So much more than gluten-free
New Face of Retail - Going out of Focus
One-stop shop nix
Prebiotics - BENEFICIAL BACTERIA
Sugar Reduction - Toolbox of TASTE
Reduced sugar with the label in mind
Artisan Tech - AUTOMATED JUST RIGHT
Continuous improvement with automation
Cooling and Freezing - NIPPING it in the bud
Designing a freezer for future demand
Third-Party Solutions - PEAK PERSPECTIVE
Variety Packs - making GOOD CHOICES
INDUSTRY INSIGHT - DEVELOPING IN-HOUSE TALENT
Meeting Preview: Pack Expo International - POWER OF PACKAGING
Meeting Preview: AACC International - GLOBE-TROTTING CHEMISTS
Events
Featured Innovation Center
Ingredients & Formulating
Equipment & Packaging
Patents
New on the Shelf
MARKETPLACE
AD INDEX
NEW PRODUCT SPOTLIGHT
Baking & Snack - July 2018 - Baking & Snack - July 2018
Baking & Snack - July 2018 - Baking & Snack - July 2018
Baking & Snack - July 2018 - FC - 1
Baking & Snack - July 2018 - FC - 2
Baking & Snack - July 2018 - 2
Baking & Snack - July 2018 - 3
Baking & Snack - July 2018 - 4
Baking & Snack - July 2018 - 5
Baking & Snack - July 2018 - 6
Baking & Snack - July 2018 - 7
Baking & Snack - July 2018 - 8
Baking & Snack - July 2018 - Contents
Baking & Snack - July 2018 - 10
Baking & Snack - July 2018 - Contents
Baking & Snack - July 2018 - Editorial - Unexpected perks of the job
Baking & Snack - July 2018 - 13
Baking & Snack - July 2018 - 14
Baking & Snack - July 2018 - 15
Baking & Snack - July 2018 - Paxiom opens fifth Xperience Center
Baking & Snack - July 2018 - 17
Baking & Snack - July 2018 - In Memoriam
Baking & Snack - July 2018 - People/In Brief
Baking & Snack - July 2018 - 20
Baking & Snack - July 2018 - 21
Baking & Snack - July 2018 - 22
Baking & Snack - July 2018 - iba - HOME AWAY FROM HOME
Baking & Snack - July 2018 - 24
Baking & Snack - July 2018 - 25
Baking & Snack - July 2018 - iba 2018: US Pavilion Booth Previews
Baking & Snack - July 2018 - 27
Baking & Snack - July 2018 - 28
Baking & Snack - July 2018 - 29
Baking & Snack - July 2018 - 30
Baking & Snack - July 2018 - 31
Baking & Snack - July 2018 - 32
Baking & Snack - July 2018 - 33
Baking & Snack - July 2018 - iba 2018: International Booth Previews
Baking & Snack - July 2018 - 35
Baking & Snack - July 2018 - 36
Baking & Snack - July 2018 - 37
Baking & Snack - July 2018 - 38
Baking & Snack - July 2018 - 39
Baking & Snack - July 2018 - 40
Baking & Snack - July 2018 - 41
Baking & Snack - July 2018 - Canyon Bakehouse - REUNITED!
Baking & Snack - July 2018 - 43
Baking & Snack - July 2018 - The art of product development
Baking & Snack - July 2018 - 45
Baking & Snack - July 2018 - 46
Baking & Snack - July 2018 - 47
Baking & Snack - July 2018 - 48
Baking & Snack - July 2018 - 49
Baking & Snack - July 2018 - So much more than gluten-free
Baking & Snack - July 2018 - 51
Baking & Snack - July 2018 - 52
Baking & Snack - July 2018 - 53
Baking & Snack - July 2018 - 54
Baking & Snack - July 2018 - 55
Baking & Snack - July 2018 - 56
Baking & Snack - July 2018 - New Face of Retail - Going out of Focus
Baking & Snack - July 2018 - 58
Baking & Snack - July 2018 - 59
Baking & Snack - July 2018 - One-stop shop nix
Baking & Snack - July 2018 - 61
Baking & Snack - July 2018 - 62
Baking & Snack - July 2018 - 63
Baking & Snack - July 2018 - 64
Baking & Snack - July 2018 - 65
Baking & Snack - July 2018 - 66
Baking & Snack - July 2018 - Prebiotics - BENEFICIAL BACTERIA
Baking & Snack - July 2018 - 68
Baking & Snack - July 2018 - 69
Baking & Snack - July 2018 - 70
Baking & Snack - July 2018 - 71
Baking & Snack - July 2018 - 72
Baking & Snack - July 2018 - 73
Baking & Snack - July 2018 - 74
Baking & Snack - July 2018 - Sugar Reduction - Toolbox of TASTE
Baking & Snack - July 2018 - 76
Baking & Snack - July 2018 - 77
Baking & Snack - July 2018 - 78
Baking & Snack - July 2018 - 79
Baking & Snack - July 2018 - Reduced sugar with the label in mind
Baking & Snack - July 2018 - 81
Baking & Snack - July 2018 - 82
Baking & Snack - July 2018 - Artisan Tech - AUTOMATED JUST RIGHT
Baking & Snack - July 2018 - 84
Baking & Snack - July 2018 - 85
Baking & Snack - July 2018 - 86
Baking & Snack - July 2018 - 87
Baking & Snack - July 2018 - Continuous improvement with automation
Baking & Snack - July 2018 - 89
Baking & Snack - July 2018 - 90
Baking & Snack - July 2018 - 91
Baking & Snack - July 2018 - 92
Baking & Snack - July 2018 - 93
Baking & Snack - July 2018 - 94
Baking & Snack - July 2018 - Cooling and Freezing - NIPPING it in the bud
Baking & Snack - July 2018 - Designing a freezer for future demand
Baking & Snack - July 2018 - 97
Baking & Snack - July 2018 - 98
Baking & Snack - July 2018 - 99
Baking & Snack - July 2018 - 100
Baking & Snack - July 2018 - 101
Baking & Snack - July 2018 - 102
Baking & Snack - July 2018 - 103
Baking & Snack - July 2018 - 104
Baking & Snack - July 2018 - Third-Party Solutions - PEAK PERSPECTIVE
Baking & Snack - July 2018 - 106
Baking & Snack - July 2018 - 107
Baking & Snack - July 2018 - 108
Baking & Snack - July 2018 - 109
Baking & Snack - July 2018 - 110
Baking & Snack - July 2018 - Variety Packs - making GOOD CHOICES
Baking & Snack - July 2018 - 112
Baking & Snack - July 2018 - 113
Baking & Snack - July 2018 - 114
Baking & Snack - July 2018 - 115
Baking & Snack - July 2018 - 116
Baking & Snack - July 2018 - 117
Baking & Snack - July 2018 - 118
Baking & Snack - July 2018 - 119
Baking & Snack - July 2018 - 120
Baking & Snack - July 2018 - INDUSTRY INSIGHT - DEVELOPING IN-HOUSE TALENT
Baking & Snack - July 2018 - 122
Baking & Snack - July 2018 - Meeting Preview: Pack Expo International - POWER OF PACKAGING
Baking & Snack - July 2018 - 124
Baking & Snack - July 2018 - Meeting Preview: AACC International - GLOBE-TROTTING CHEMISTS
Baking & Snack - July 2018 - Events
Baking & Snack - July 2018 - 127
Baking & Snack - July 2018 - 128
Baking & Snack - July 2018 - 129
Baking & Snack - July 2018 - Featured Innovation Center
Baking & Snack - July 2018 - 131
Baking & Snack - July 2018 - 132
Baking & Snack - July 2018 - Ingredients & Formulating
Baking & Snack - July 2018 - 134
Baking & Snack - July 2018 - 135
Baking & Snack - July 2018 - Equipment & Packaging
Baking & Snack - July 2018 - 137
Baking & Snack - July 2018 - 138
Baking & Snack - July 2018 - Patents
Baking & Snack - July 2018 - 140
Baking & Snack - July 2018 - New on the Shelf
Baking & Snack - July 2018 - 142
Baking & Snack - July 2018 - MARKETPLACE
Baking & Snack - July 2018 - 144
Baking & Snack - July 2018 - 145
Baking & Snack - July 2018 - 146
Baking & Snack - July 2018 - 147
Baking & Snack - July 2018 - 148
Baking & Snack - July 2018 - 149
Baking & Snack - July 2018 - 150
Baking & Snack - July 2018 - 151
Baking & Snack - July 2018 - 152
Baking & Snack - July 2018 - AD INDEX
Baking & Snack - July 2018 - NEW PRODUCT SPOTLIGHT
Baking & Snack - July 2018 - 155
Baking & Snack - July 2018 - 156
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