Baking & Snack - August 2019 - 150

MULTIPACKS

Putting the variety in multipacks
It's more exciting to have a crayon
box with different colors than a pack
with only blue ones. The same can be
true of consumers and bulk snacks
especially. Although multipacks aren't
going anywhere, variety packs are
increasing in demand. In fact, according to the 2018 "Snack Foods
- Packaging and Processing Market
Assessment and Trends" report from
PMMI, flavor variety is one of the top
consumer snacking trends.
Dennis Gunnell, president,
Formost Fuji, said a snack manufacturer might consider mixing it up.
"You might have potato chips, corn
chips and tortilla chips in the same
pack," he said. "Or you might have
peanut butter sandwich crackers
with cheese crackers."
Now, snack producers are making
variety packs ranging from two to
seven flavors, and some with unbalanced counts inside the carton or bag,
reported Nico Roesler, managing editor of Baking & Snack, in the February
issue of Snac World. The variance
with big box snacks provides options
for the whole family.
However, variety packs come with
their own challenges in addition to
the obstacles with multipacks. One
problem occurs in the packaging line.
"When you have several lines running to build a multipack with various
flavors, the risk of total line shutdown
increases," said Guilherme Vivona,
director of South American operations at BluePrint Automation. "One
line can affect the entire multipack
operation. Additionally, there have
been instances where a decrease in
efficiency has been reported."
Companies should also be aware
that storage can be a big problem.
"Where do you store product while
you're building up inventory of each
flavor to create your variety pack?"
Mr. Gunnell said. Calculating the
space needed is crucial before making
the decision to provide various flavors
in the same container.

150 Baking & Snack August 2019 / www.bakingandsnack.com

gether and provide greater strength.
Snacks are more stable and require
fewer packaging layers. Granola bars
are thick and easily stacked. Mr. Kehrli
said crackers should also be targeted
for multipacks because, despite their
seemingly fragile composition, the
edges are strong. This strength increases when tightly flowwrapped together,
stacked and placed on their side.
The most common secondary packaging for multipacks is regular slotted
cases (RSC), according to Guilherme
Vivona, director of South American operations, BluePrint Automation (BPA).
"In South America, most of those cases
are nicknamed 'boomerang,' as they
can be used several times," he said. "In
the US, they are referred to as reusable cases."
Some single-wrapped snacks have
enough stability with just a standard flowwrapper. This is common
in Europe and Latin America, where
manufacturers are eliminating cartons. "They seem to have a lot more
multipacks than we do. For a stack of
crackers, they typically would not put
those in a carrier tray. With a 12-pack,
for example, they try and reduce the
cost by just overwrapping it in another
layer of material," Mr. Gunnell said.
In the US, products are put in a primary flowwrap, then a carton and a
case, which are palletized and shipped.
Despite the innovation of carton and
case removal, US producers haven't
been able to part with them. Mr. Kehrli
has seen some flowwrapped multipacks in the US made by international
companies that have reduced packaging. This allows them to sell multipacks in dollar stores, which have such
a low price point that the packaging
cost can easily outweigh product cost.
E-commerce is driving innovation
in multipack materials. "I see change
coming for packaging," Mr. Kehrli
said. "As we get away from the grocery store and do more business with
e-commerce, shipping has to be done
in a different way. We don't need cartons. Multipack with flowwrap saves

space, includes more product and is
more efficient, driving costs down."
With e-commerce, consumers are
offered customization with multipacks
such as choosing the quantity, sizes
and flavors. "Producers must be prepared to accommodate these orders
while maintaining efficiency and cost,"
Mr. Vivona said. "This can be a challenge and where a versatile packing solution comes into play."

Machines for the masses
In addition to packaging issues, putting products into multipacks comes
with other challenges. Equipment offers solutions, but with multipacks,
there might be some give-and-take.
"First, you will want a very efficient
indexing system that will correctly
count each product and align them perfectly to be packed," Mr. Vivona stated.
"Second, note that in a multipack system all lines are dependent of each other. If one bagger fails to send its products, the system must shut down until
the failed line comes back up, reducing
plant efficiency."
Higher speeds and efficiency are always common requests. "Producers have
typically relied on manual labor to hand
pack their multipacks," Mr. Vivona said.
"Now producers are looking for reliable
technologies that can replace those people for a safer, more cost-efficient and
productive result."
BPA uses vision-guided robotics to
pick and place items onto an infeed
line, wrapper chain or directly into the
secondary container. "It is quite common for a single secondary packaging
machine to be fed from more than one
bagger," Mr. Vivona noted. "With multipacks, this is not the case. Complexity
increases when it comes to different
SKUs being packed on a single, secondary packaging system."
Cavanna will showcase systems
at the International Baking Industry
Exposition (IBIE), held Sept. 7-11 in
Las Vegas, for bar, snack cake, cookie
and cracker multipacks. Some are
robotic-based and can put product to-


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Baking & Snack - August 2019

Table of Contents for the Digital Edition of Baking & Snack - August 2019

Baking & Snack - August 2019
Contents
Contents
Editorial - A tale of two bakeries
Newsfront - Great Harvest testing home bread delivery
General Mills shifts focus to speed to market
Bunge in partnership to measure sustainability
News - Five trends impacting bakery and snack packaging
Atlas Holdings to purchase snacks unit from TreeHouse
Multivac acquires Fritsch Group
Middleby acquires Packaging Progressions
Ferrero to acquire Campbell Soup’s Kelsen Group
People/In Brief
Food Safety Series - the ALLERGEN piece
Klosterman Baking Co. - ANOTHER HISTORIC MILESTONE
Creating a buzz around a cause
Chabaso - the influential Loaf
Chabaso’s wheat seminar meets ‘ag in the middle’
International Series: Europe - NO TASTE LIKE HOME
Mixes and Bases - ELIMINATING ERRORS
Chocolate - crafting cocoa to expectations
The long road to sustainable cocoa
TECHNICALLY SPEAKING - SANITARY DESIGN made easy
Cake Processing - INTO THIN AIR
Pyler Says: Batter specific gravity
Depanning - CATCH AND RELEASE
ABA takes major step to fight tray theft
Slicing - Making the cut
Continuous Improvement - Good...Better...BEST
Equipment’s role in continuous improvement
Multipacks - Multidimensional MULTIPACKS
Putting the variety in multipacks
Vehicles - efficiency ON THE ROAD
ABA heads IBIE logistics conference
The future of commercial vehicles
SANITATION STRATEGIES - EXPANDING 5S
INDUSTRY IMAGES: IFT - the future is NOW
INDUSTRY IMAGES: BEMA - ALL-TIME HIGH
Meeting Preview: CASBA - Worthy Celebration
The Kit Murphy Memorial Scholarship
Meeting Preview: IBIE - THE TIME HAS COME
Meeting Preview: ABA Technical Conference - EMPOWERING BAKERS
Events
Featured Innnovation Center
Ingredients & Formulating
Equipment & Packaging
Patents
New on the Shelf
MARKETPLACE
AD INDEX
AD INDEX
NEW PRODUCT SPOTLIGHT
Baking & Snack - August 2019 - Baking & Snack - August 2019
Baking & Snack - August 2019 - Baking & Snack - August 2019
Baking & Snack - August 2019 - FC - 1
Baking & Snack - August 2019 - FC - 2
Baking & Snack - August 2019 - 2
Baking & Snack - August 2019 - 3
Baking & Snack - August 2019 - 4
Baking & Snack - August 2019 - 5
Baking & Snack - August 2019 - 6
Baking & Snack - August 2019 - 7
Baking & Snack - August 2019 - 8
Baking & Snack - August 2019 - Contents
Baking & Snack - August 2019 - 10
Baking & Snack - August 2019 - Contents
Baking & Snack - August 2019 - Editorial - A tale of two bakeries
Baking & Snack - August 2019 - 13
Baking & Snack - August 2019 - 14
Baking & Snack - August 2019 - 15
Baking & Snack - August 2019 - Bunge in partnership to measure sustainability
Baking & Snack - August 2019 - 17
Baking & Snack - August 2019 - Multivac acquires Fritsch Group
Baking & Snack - August 2019 - 19
Baking & Snack - August 2019 - Ferrero to acquire Campbell Soup’s Kelsen Group
Baking & Snack - August 2019 - 21
Baking & Snack - August 2019 - People/In Brief
Baking & Snack - August 2019 - 23
Baking & Snack - August 2019 - 24
Baking & Snack - August 2019 - 25
Baking & Snack - August 2019 - 26
Baking & Snack - August 2019 - Food Safety Series - the ALLERGEN piece
Baking & Snack - August 2019 - 28
Baking & Snack - August 2019 - 29
Baking & Snack - August 2019 - 30
Baking & Snack - August 2019 - 31
Baking & Snack - August 2019 - 32
Baking & Snack - August 2019 - 33
Baking & Snack - August 2019 - 34
Baking & Snack - August 2019 - 35
Baking & Snack - August 2019 - 36
Baking & Snack - August 2019 - 37
Baking & Snack - August 2019 - Klosterman Baking Co. - ANOTHER HISTORIC MILESTONE
Baking & Snack - August 2019 - 39
Baking & Snack - August 2019 - 40
Baking & Snack - August 2019 - 41
Baking & Snack - August 2019 - 42
Baking & Snack - August 2019 - 43
Baking & Snack - August 2019 - 44
Baking & Snack - August 2019 - 45
Baking & Snack - August 2019 - 46
Baking & Snack - August 2019 - 47
Baking & Snack - August 2019 - 48
Baking & Snack - August 2019 - 49
Baking & Snack - August 2019 - Creating a buzz around a cause
Baking & Snack - August 2019 - 51
Baking & Snack - August 2019 - 52
Baking & Snack - August 2019 - 53
Baking & Snack - August 2019 - 54
Baking & Snack - August 2019 - 55
Baking & Snack - August 2019 - 56
Baking & Snack - August 2019 - Chabaso - the influential Loaf
Baking & Snack - August 2019 - 58
Baking & Snack - August 2019 - 59
Baking & Snack - August 2019 - 60
Baking & Snack - August 2019 - 61
Baking & Snack - August 2019 - Chabaso’s wheat seminar meets ‘ag in the middle’
Baking & Snack - August 2019 - 63
Baking & Snack - August 2019 - 64
Baking & Snack - August 2019 - 65
Baking & Snack - August 2019 - 66
Baking & Snack - August 2019 - 67
Baking & Snack - August 2019 - 68
Baking & Snack - August 2019 - International Series: Europe - NO TASTE LIKE HOME
Baking & Snack - August 2019 - 70
Baking & Snack - August 2019 - 71
Baking & Snack - August 2019 - 72
Baking & Snack - August 2019 - 73
Baking & Snack - August 2019 - 74
Baking & Snack - August 2019 - 75
Baking & Snack - August 2019 - 76
Baking & Snack - August 2019 - 77
Baking & Snack - August 2019 - 78
Baking & Snack - August 2019 - Mixes and Bases - ELIMINATING ERRORS
Baking & Snack - August 2019 - 80
Baking & Snack - August 2019 - 81
Baking & Snack - August 2019 - 82
Baking & Snack - August 2019 - 83
Baking & Snack - August 2019 - 84
Baking & Snack - August 2019 - 85
Baking & Snack - August 2019 - 86
Baking & Snack - August 2019 - 87
Baking & Snack - August 2019 - 88
Baking & Snack - August 2019 - 89
Baking & Snack - August 2019 - 90
Baking & Snack - August 2019 - 91
Baking & Snack - August 2019 - 92
Baking & Snack - August 2019 - 93
Baking & Snack - August 2019 - 94
Baking & Snack - August 2019 - Chocolate - crafting cocoa to expectations
Baking & Snack - August 2019 - The long road to sustainable cocoa
Baking & Snack - August 2019 - 97
Baking & Snack - August 2019 - 98
Baking & Snack - August 2019 - 99
Baking & Snack - August 2019 - 100
Baking & Snack - August 2019 - 101
Baking & Snack - August 2019 - 102
Baking & Snack - August 2019 - 103
Baking & Snack - August 2019 - 104
Baking & Snack - August 2019 - TECHNICALLY SPEAKING - SANITARY DESIGN made easy
Baking & Snack - August 2019 - 106
Baking & Snack - August 2019 - Cake Processing - INTO THIN AIR
Baking & Snack - August 2019 - 108
Baking & Snack - August 2019 - 109
Baking & Snack - August 2019 - 110
Baking & Snack - August 2019 - 111
Baking & Snack - August 2019 - 112
Baking & Snack - August 2019 - 113
Baking & Snack - August 2019 - Pyler Says: Batter specific gravity
Baking & Snack - August 2019 - 115
Baking & Snack - August 2019 - 116
Baking & Snack - August 2019 - 117
Baking & Snack - August 2019 - 118
Baking & Snack - August 2019 - Depanning - CATCH AND RELEASE
Baking & Snack - August 2019 - 120
Baking & Snack - August 2019 - ABA takes major step to fight tray theft
Baking & Snack - August 2019 - 122
Baking & Snack - August 2019 - 123
Baking & Snack - August 2019 - 124
Baking & Snack - August 2019 - 125
Baking & Snack - August 2019 - 126
Baking & Snack - August 2019 - 127
Baking & Snack - August 2019 - 128
Baking & Snack - August 2019 - Slicing - Making the cut
Baking & Snack - August 2019 - 130
Baking & Snack - August 2019 - 131
Baking & Snack - August 2019 - 132
Baking & Snack - August 2019 - 133
Baking & Snack - August 2019 - 134
Baking & Snack - August 2019 - 135
Baking & Snack - August 2019 - 136
Baking & Snack - August 2019 - 137
Baking & Snack - August 2019 - 138
Baking & Snack - August 2019 - Continuous Improvement - Good...Better...BEST
Baking & Snack - August 2019 - 140
Baking & Snack - August 2019 - 141
Baking & Snack - August 2019 - 142
Baking & Snack - August 2019 - 143
Baking & Snack - August 2019 - Equipment’s role in continuous improvement
Baking & Snack - August 2019 - 145
Baking & Snack - August 2019 - 146
Baking & Snack - August 2019 - 147
Baking & Snack - August 2019 - 148
Baking & Snack - August 2019 - Multipacks - Multidimensional MULTIPACKS
Baking & Snack - August 2019 - Putting the variety in multipacks
Baking & Snack - August 2019 - 151
Baking & Snack - August 2019 - 152
Baking & Snack - August 2019 - 153
Baking & Snack - August 2019 - Vehicles - efficiency ON THE ROAD
Baking & Snack - August 2019 - ABA heads IBIE logistics conference
Baking & Snack - August 2019 - The future of commercial vehicles
Baking & Snack - August 2019 - 157
Baking & Snack - August 2019 - 158
Baking & Snack - August 2019 - SANITATION STRATEGIES - EXPANDING 5S
Baking & Snack - August 2019 - 160
Baking & Snack - August 2019 - INDUSTRY IMAGES: IFT - the future is NOW
Baking & Snack - August 2019 - 162
Baking & Snack - August 2019 - 163
Baking & Snack - August 2019 - 164
Baking & Snack - August 2019 - INDUSTRY IMAGES: BEMA - ALL-TIME HIGH
Baking & Snack - August 2019 - 166
Baking & Snack - August 2019 - 167
Baking & Snack - August 2019 - 168
Baking & Snack - August 2019 - 169
Baking & Snack - August 2019 - Meeting Preview: CASBA - Worthy Celebration
Baking & Snack - August 2019 - The Kit Murphy Memorial Scholarship
Baking & Snack - August 2019 - 172
Baking & Snack - August 2019 - Meeting Preview: IBIE - THE TIME HAS COME
Baking & Snack - August 2019 - 174
Baking & Snack - August 2019 - 175
Baking & Snack - August 2019 - 176
Baking & Snack - August 2019 - Meeting Preview: ABA Technical Conference - EMPOWERING BAKERS
Baking & Snack - August 2019 - Events
Baking & Snack - August 2019 - 179
Baking & Snack - August 2019 - 180
Baking & Snack - August 2019 - 181
Baking & Snack - August 2019 - Featured Innnovation Center
Baking & Snack - August 2019 - 183
Baking & Snack - August 2019 - Ingredients & Formulating
Baking & Snack - August 2019 - 185
Baking & Snack - August 2019 - 186
Baking & Snack - August 2019 - 187
Baking & Snack - August 2019 - 188
Baking & Snack - August 2019 - 189
Baking & Snack - August 2019 - Equipment & Packaging
Baking & Snack - August 2019 - 191
Baking & Snack - August 2019 - 192
Baking & Snack - August 2019 - 193
Baking & Snack - August 2019 - 194
Baking & Snack - August 2019 - 195
Baking & Snack - August 2019 - 196
Baking & Snack - August 2019 - 197
Baking & Snack - August 2019 - Patents
Baking & Snack - August 2019 - 199
Baking & Snack - August 2019 - 200
Baking & Snack - August 2019 - 201
Baking & Snack - August 2019 - New on the Shelf
Baking & Snack - August 2019 - 203
Baking & Snack - August 2019 - 204
Baking & Snack - August 2019 - 205
Baking & Snack - August 2019 - MARKETPLACE
Baking & Snack - August 2019 - 207
Baking & Snack - August 2019 - 208
Baking & Snack - August 2019 - 209
Baking & Snack - August 2019 - 210
Baking & Snack - August 2019 - 211
Baking & Snack - August 2019 - 212
Baking & Snack - August 2019 - 213
Baking & Snack - August 2019 - 214
Baking & Snack - August 2019 - 215
Baking & Snack - August 2019 - AD INDEX
Baking & Snack - August 2019 - AD INDEX
Baking & Snack - August 2019 - NEW PRODUCT SPOTLIGHT
Baking & Snack - August 2019 - 219
Baking & Snack - August 2019 - 220
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