Cocoa distributor sweetens packaging operations

This article was published in Modern’s 2011 Casebook.

It can be hard enough to stack pallets and safely transport materials when they’re packaged in boxes. But for a cocoa manufacturer, stacked bags of cocoa powder present an assortment of shipping challenges. Barry Callebaut, one of the world’s leading manufacturers of cocoa and chocolate products, installed a packaging solution (Beumer, 732-560-8222, http://www.beumer.com) that increased product safety and stack stability while reducing packaging material costs.

To ensure that the cocoa powder arrives to customers in perfect condition, it must be protected against temperature and humidity. An automated solution allowed the company to improve process reliability and product presentation. The system included a fully automated, completely pre-mounted bagging system. After the palletizing process, the stack press increases stack stability by removing residual air from the bags.

This high-capacity packaging system then pulls a stretch hood over the palletized bag stack to protect the products against wind, rain and dust while providing safety and stability during transport. Sensors on the stretch hood measure the height of the pallet. This automation allows for the calculation of different stacking heights as well as the optimization of packing film.

Since the modernization, the Barry Callebaut’s packaging facility became the fifth recipient of an annual Packaging Line of the Year Award for its end-of-line packaging solution. More importantly, customers receive a product protected against wind, rain and dust. The material costs for packaging have been reduced by 5% to 10%, making this solution cost effective and environmentally friendly.