Packaging technologies for bread and bakery production

For the manufacture of a wide range of bakery products, when it comes to packaging, in addition to making the items easy to store and transport, keeping them fresh and free from contamination is a key factor to consider when using packaging technologies for bread production. In recent years, producers in the food and food packaging industries, the medical and pharmaceutical industries and manufacturers of technical products have increasingly turned to flow wrap to package and protect their products. Flow wrapping is a horizontal movement process in which bread in any format is wrapped in transparent or printed polypropylene film. The end result is a flexible pack for preserving bread with a no-twist type seal on the bottom seals and pleated ends.

Manufacturers of packaging machinery and technologies for the production of bread and bakery products are committed to following packaging trends in a wide range of bread types, and their range of packaging equipment includes horizontal flow wrappers for pillow wrapping, especially for bakery products. These flow pack machines are designed to provide an efficient and automated solution for packaging a wide range of bakery products.

Why companies in the sector need new technological alternatives for bread packaging 

• Flow wrapper technologies help to reduce packaging costs: In any industrial bakery industry, competition is fierce, so it is essential to gain cost advantages over competitors and to have a smart manufacturing in the food sector. Switching to an automated flow wrapping solution helps to reduce costs and make packaging processes more efficient.
• Flow wrappers help to preserve food products: A horizontal flow wrapper helps preserve and protect a wide range of products such as bread and pastries by providing an airtight seal against oxygen. Gas flush technology can also be used to help produce a protective atmosphere to increase the shelf life of products.
  The flow wrap also helps to restrict the movement of a product inside the package, preventing it from being altered or damaged.
• Flow wraps make transit and display orderly: Flow-wrapped products can be neatly packaged, either in outer packaging for transit or storage, or displayed on a retail shelf, without the need for additional resources.
• Packaging technologies for bread production help increase margins: Flow wrapping allows industrial bakery products to be sold in smaller quantities, rather than in bulk. As a result, selling smaller units generates higher margins and creates added product value.
• Flow-wrap packaging technologies help prevent contamination: For products in the food industries, protecting products from external contamination is extremely important for the safety of the consumer or end users. Flow wrap provides a protective barrier and seal.
• Bread packaging machines with horizontal flow technology pack large orders in short periods of time: An automated flow wrapping system enables companies to react quickly to customer orders and achieve complete packaging of even large orders in a short period of time. As a result, short lead times can be met, making businesses more attractive to customers and helping them grow by packaging higher volumes of products.

Flexible bread packaging solutions for a wide range of bakery products

A particular case that may be of interest in explaining packaging technologies for the production of bread and pastries is that of a multinational manufacturer of sweet bakery products. The products they work with are: muffins, cakes, croissants and a wide range of delicate bakery products that must be handled with care, from distribution to primary packaging. Therefore the challenge for the production manager of this company was to rely on the implementation of integrated packaging systems within their plant.

Maximum flexibility for a wide range of bread and bakery products

The production manager needed several flow wrapping machines for the primary packaging of baked goods. He ended up purchasing a packaging line capable of packaging a wide variety of bakery products such as bread, hamburger buns, sandwich rolls, puff pastries, croissants, sandwiches, cupcakes, muffins, Swiss rolls, rolls and cake bars.

The production manager was looking for packaging technology for the production of flexible bread that could easily adapt to different shapes and textures of his products. On the one hand, he had commented that he wanted machines that worked efficiently, had short downtimes and simple format changeovers. On the other hand, the processing and packaging of unique and delicate products had to be taken into account.

They ended up acquiring two bread and pastry packaging machines that could easily adapt to the wide range of products in terms of handling, distribution, feeding and packaging, further improving production output.

As the production process of this industrial bakery company was complex from production to packaging, efficient manufacturing was required, where the production and packaging processes should be precisely coordinated and interoperate smoothly. Therefore, the production manager needed a quality interface to take over the upstream equipment that transfers the baked products to the packaging machines after the manufacturing process. This integrative process is particularly difficult with products such as muffins.

After baking, the cupcakes come out of the oven every 20 to 30 seconds and are conveyed through a cooling tunnel before being wrapped by the bread and pastry wrapping machines. They are handled and distributed to the flow wrapping machines depending on the texture of the products. The wrapping machine is designed for optimal production speed and to handle the products faster. Products such as muffins are distributed in a way that prevents them from tipping over.

The cupcakes are then placed on a conveyor belt that transports them to a bundle feeder, which aligns and positions them for further transport to the flow wrapping machine. The horizontal flow wrapper packs the cupcakes individually or in double packs. From here, a conveyor belt transports the products to the downstream secondary packaging equipment.

The production manager commented that they were able to fully integrate the primary packaging system into the production process and thus ensured a smooth transition from baking to primary packaging, without time loss and with efficiency.

All flow wrappers implemented offered the necessary flexibility for the company's wide range of products. The bread packaging machines were combined with different distribution and feeding systems to take into account the individual needs of each bakery product. A key performance factor for the flow wrappers was their sealing effectiveness.

Test procedures for bread and industrial bakery packaging machines

It is essential to maintain a trusting partnership between the machine manufacturer and the person responsible for the implementation of the machine in the industrial plant. In this way, maximum line efficiency can be achieved. Intensive procedures, such as leak testing of the flow wrappers for the different baked products, are relevant for the best possible result in the packaging of the products. We recommend plant managers in industrial bakery manufacturing to demand reliable service and solutions such as virtual remote support, which are especially useful in today's environment.

New packaging machines and technologies for bread and bakery production provide a complete overview of the entire production environment, enabling any company in the sector to respond to changes in packaging and market demand very quickly. After-sales support is a key factor to consider before purchasing a packaging machine, so they are there for you every step of the way, from packaging line design through project management and from installation to maintenance.

If you want to know more about the real cost of an end-of-line palletiser robot and the new packaging technologies for bread production, subscribe to the technology newsletter for industry.