Baking & Snack - March 2021 - 88

HFFS PACKAGING

HFFS machines must
maintain the quality
of fragile baked
foods, especially
on high-volume
production lines.
Formost Fuji Corp.

information such as product weight and ingredients.
" Next to film material also sealing time is important, "
Mr. Schildknecht said. " This determines the speed per
wrapping line and ultimately the amount of wrapping
lines needed for a solution. "
Determining how to seal packaging depends on a bakery's top priorities, said Jerry Buckley, south central sales manager, BluePrint Automation (BPA).
" If seal integrity is the most important factor, then
heat sealing may likely be the best choice, " he said. " If
speed is the required factor, then cold sealing is commonly a better choice. "

Packing in variety
During the pandemic, variety packs have increased in
popularity as more people work and learn from home.
Offering consumers these packs - strawberry and blueberry muffins in one package - sounds like a straightforward proposition, but it's not.
Bakeries generally have two options to produce them.
The first is to run each product separately, then place
them in totes, trays or cartons, ship them to a storage
facility or elsewhere in the production warehouse, then
carton them manually or through an automated system.
" If you are looking for a more manual solution, the
challenges are minimal but require significant labor
costs, " Mr. Becker said.
This option also often creates waste as the products
are sometimes placed in retail cartons, which must later
be opened and thrown away or recycled, Mr. Kehrli said.
Or they are placed in totes or trays, which then must be
taken back to the production facility to be used again.
The second alternative is to run both products in sideby-side ovens, then the products are cooled, individually wrapped and put into cartons together right away.
Both production lines need to run at the same speed.
However, if one line has a problem and must be stopped
while the other is still running, bakeries must deal with
the overflow until the other line is restored. This can include redundant or accumulation systems.
" In an ideal world, the bakery industry would

88 Baking & Snack March 2021 / www.bakingbusiness.com

love to have oven A and oven B and go directly into
a variety pack. It's common sense, right? " Mr. Kehrli
said. " Ninety-five percent of the bakery industry and
other industries where there's variety go from oven
A into storage, oven B into storage, then they marry
together at [another facility]. And they have a bunch
of people or some level of automation creating that
variety pack. "
When cartoning variety packs, bakers should ensure
the code date on the outside carton is good for all varieties in the package and that the orientation in the box
doesn't negatively affect the product quality, including
ensuring that fragile products aren't crushed or broken.
" You wouldn't want to put the softest product on the
bottom of the carton, " Mr. Becker said.
If bakeries are handling different carton sizes, such as
8- and 24-count variety packs, the equipment must be
flexible enough to handle the switch and fast enough to
accommodate customers' needs. And larger sizes can
be more challenging because the amount of air in an
HFFS package varies. That variance in a 24-count box
is much greater than in one with only eight items, Mr.
Kehrli said.
And care must also be given to conveyors transporting cartons to the case-packing operation as smaller cartons can rotate en route, Mr. Becker said.
When bakeries are moving from bulk to HFFS packaging, they have several considerations to weigh, and figuring out the best solutions means consulting all the people
involved in the process of making the baked goods.
" Don't talk to your equipment guys over here, your
film people over here, your consumer over here, " Mr.
Gunnell said. " Get everybody together and say, 'OK,
here is what we want to end up with. What challenges
do you see?' "
Talking to the experts and others in the industry who
have made the switch is critical, Mr. Kerhli said. This
will help avoid common pitfalls and keep projects moving in the right direction.
" Start educating yourself, " Mr. Kehrli said. " You are
not going to find it on YouTube. "

*


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Baking & Snack - March 2021

Table of Contents for the Digital Edition of Baking & Snack - March 2021

Baking & Snack - March 2021 - Intro
Baking & Snack - March 2021 - 1
Baking & Snack - March 2021 - 2
Baking & Snack - March 2021 - 3
Baking & Snack - March 2021 - 4
Baking & Snack - March 2021 - 5
Baking & Snack - March 2021 - 6
Baking & Snack - March 2021 - 7
Baking & Snack - March 2021 - 8
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