Case
studies

1

Consulting/
Concept design

Cereal Bar Production Line

PROBLEM TO BE SOLVED

Customer wanted to move from highly manual process of cereal bar making to semi-automatic to increase line output. Cereal bar consists of mixture of powder and dired fruits with addition of liquids. When dough is mixed it is inserted in forms. Next steps of production process takes baking in oven. After baking cake was cut with casts to obtain desired bar shapes. Product was picked manually inserted in pre-made packaging and closed on sealing machine. Packing into secondary and palletization is done manually.
From: 10kg/h; batch process; 4 FTE
To: 100kg/h; continous batch process; 2 FTE

PROPOSED DESIGN

FIDES team was encouraged to propose two concepts. First one which could be an intermediate stage so called semi-automatic and second stage as a fully automatic solution. In first stage we focused in designing a lean design line with straight overlook for better operation and maintenance. Dough was formed separately into batches stored in containers. Main machine design was buffering dough for even and continous distribution on belt via rotary molder. Slab is transported on belt to cooling tunnel for moisture control and formed by cutter. During transport on belt FIDES helped to determine Metaldetector to check against metal contamination. Bars were collated and transported to chain conveyor as infeed to flow wrap machine with speed around 30 bars per minute.

Second and final stage of concept added automatic batch assembly system with 8 holding bins for raw materials and recipe control. System was prepared to be developed for additional flavours and extension in future. Batch would be continously discharged to first stage of project. Packing end was equipped with carton erecting, filling, and closing machine. Product in cartons had possibility to re-route between hand stacking and potential future development of tertiary cartoning for use in e-commerce.

Deliverables:

  • Process description,
  • Technical datasheet,
  • List of proposed suppliers,
  • Layouts fitting into available production hall space,
  • Budget estimates,
  • Timeline for implementation