B&CMA 91 st Technical Conference – Atlanta, GA

B&CMA 91st Technical Conference – Atlanta, GA The future of Capping By Marnus Rotte Commercial Director at Houdijk Holland in the Netherlands May 2nd, 2016 B&CMA 91st Technical Conference – Atlanta, GA

B&CMA 91st Technical Conference – Atlanta, GA The future of Capping Agenda: Capper vs. Creamer sandwich technology Position of Capper in the production line General functionality capping systems Required functionality to optimize capper process Benefit in efficiency B&CMA 91st Technical Conference – Atlanta, GA

B&CMA 91st Technical Conference – Atlanta, GA The future of Capping • Creamer technology: • Highest output in p.p.m. • Limited flexible in biscuit shapes and dimensions • Limited flexibility in cream possibilities • Limitations in cleanability • Connected through buffer • Capper technology: • Maximum flexibility in biscuit shapes and dimensions • Maximum flexibility in cream possibilities • Maximum cleanability • Directly connected to oven B&CMA 91st Technical Conference – Atlanta, GA

B&CMA 91st Technical Conference – Atlanta, GA The future of Capping • Position of Capper in the production line • Capper is connected direct to the oven, meaning: • + No buffer required • + No product handling required • + Best possible floor space • - No buffer to compensate missing products • - Each stop results directly to inefficiency B&CMA 91st Technical Conference – Atlanta, GA

B&CMA 91st Technical Conference – Atlanta, GA The future of Capping • Required functionality to save operators due to inefficiency process line B&CMA 91st Technical Conference – Atlanta, GA

B&CMA 91st Technical Conference – Atlanta, GA The future of Capping • Required functionality to save operators due to inefficiency process line • Automatic lane balancing Missing products from production will cause unbalance. Automatic lane balancing should temporally stop this specific lane until lane is back in balance. When it is replenished, the lane should start again in synchronization with the other lanes. Goal: No operator at entrance for balancing B&CMA 91st Technical Conference – Atlanta, GA

B&CMA 91st Technical Conference – Atlanta, GA The future of Capping • Required functionality to save operators due to inefficiency process line • No Product / No Deposit Manifold/depositor, should have individually controlled nozzles. Any missing or broken base cake should be detected and not be deposited Goal: No pollution for higher efficiency and less down time B&CMA 91st Technical Conference – Atlanta, GA

B&CMA 91st Technical Conference – Atlanta, GA The future of Capping • Required functionality to save operators due to inefficiency process line • Side alignment system (rect. product shape) No narrow channels for rectangular products alignmentwhich cause potential blockages by small crumbs, but wide and more forgiving channels. Re-alignment device to push rectangular and square base cakes sideways to their exact position. Goal: better product and higher efficiency on packing B&CMA 91st Technical Conference – Atlanta, GA

B&CMA 91st Technical Conference – Atlanta, GA The future of Capping • Required functionality to save operators due to inefficiency process line • Real time motion adjustment The base cakes and the cream are always subject to small daily (even hourly) changes. The Capper should feature an all-servo system, in which all important motions can be adjusted via the HMI in real-time. Goal: better product and higher efficiency on packing B&CMA 91st Technical Conference – Atlanta, GA

B&CMA 91st Technical Conference – Atlanta, GA The future of Capping • Required functionality to save operators due to inefficiency process line • Real time deposit weight adjustment Manifold/depositor, should have individually controlled nozzles. Any missing or broken base cake should be detected and not be deposited. Goal: better product and higher efficiency on packing + less overweight B&CMA 91st Technical Conference – Atlanta, GA

B&CMA 91st Technical Conference – Atlanta, GA The future of Capping • Required functionality to save operators due to inefficiency process line • Incomplete product discharge At the exit of the Capper, incomplete or broken sandwiches should be discharged automatically and individually. Goal: improving efficiency on packing B&CMA 91st Technical Conference – Atlanta, GA

B&CMA 91st Technical Conference – Atlanta, GA The future of Capping • Required functionality to save operators due to inefficiency process line • Poka Yoke change over Change-over should not require any tools, no mechanical adjustments, no fine-tuning, no tweaking, but only HMI recipe setting and lightweight change-over parts. Should only be done by an operator and no mechanic engineer Goal: less stand-still time B&CMA 91st Technical Conference – Atlanta, GA

B&CMA 91st Technical Conference – Atlanta, GA The future of Capping • Required functionality to save operators due to inefficiency process line • Cleaning time Completely open, hose-down design with no hidden corners or spaces and easily removable change-parts, with designated trolley for storage for a very short cleaning time. The manifold should provided with a COP-ready trolley and controls for proper HACCP cleaning. Goal: More machine availability B&CMA 91st Technical Conference – Atlanta, GA

B&CMA 91st Technical Conference – Atlanta, GA The future of Capping • Required functionality to save operators due to inefficiency process line • Vertical Start up change over A change-over may not take longer as 15 minutes – no further adjustments or tweaking should be necessary. A vertical start-up is essential to meet today’s efficiency requirements. Goal: Higher efficiency and higher machine availability B&CMA 91st Technical Conference – Atlanta, GA

B&CMA 91st Technical Conference – Atlanta, GA The future of Capping • Required functionality to save operators due to inefficiency process line • Manning level At a malfunction, all faults should be easy traceable. The cream kitchen should be positioned closely to make sure that the Capper can be manned by a single kitchen/capper operator. Goal: minimum operators costs B&CMA 91st Technical Conference – Atlanta, GA

B&CMA 91st Technical Conference – Atlanta, GA The future of Capping • Measurement in overall production efficiency and manning: • Automatic lane balancing 0,52% less waste • No Product / No Deposit 0,47% less waste, less cleaning • Side alignment system (rect. product shape) 0,22% better product • Real time motion adjustment 0,21% better product • Real time deposit weight adjustment 0,31% better product • Incomplete product discharge 0,18% performance downstream • Poka Yoke change over 1,4 hour less stand-still • Vertical start up after change over 1,1 hour quicker performance • Cleaning time 0,9 hour less stand-still • Manning level only 1 less personnel B&CMA 91st Technical Conference – Atlanta, GA

B&CMA 91st Technical Conference – Atlanta, GA The future of Capping Many thanks for your attention! Questions? B&CMA 91st Technical Conference – Atlanta, GA

B&CMA 91 st Technical Conference – Atlanta, GA