Variety packs in the snack industry are gaining popularity as consumers seek convenience, more flavors, and portion control. To meet demand, manufacturers are expanding multi-pack offerings, investing in automation to boost throughput, and taking control of the assembly process.
There are multiple ways to assemble variety packs of all different sizes, with bags packed into a case or loaded into a sack machine. Assembly can occur at the production facility, a separate warehouse, or via a co-packer.
This blog post focuses on in-house automation, highlighting three key solutions that enhance reliability, flexibility, and efficiency while reducing reliance on slow, error-prone manual processes. We’ll also share tips on determining the need for automation and choosing the right partner to support your vision.
Addressing Obstacles in Variety Pack Assembly
Adding a variety pack presents significant challenges, requiring either manual labor or automation. While manual assembly may seem cost-effective, it often leads to logistical issues, high labor costs, and frequent turnover, resulting in ongoing training and increased packing errors.
Some producers will use a third-party co-packer or distribution center to assemble the variety packs after the snacks are in their primary packaging. However, this comes with additional transportation and storage costs. Plus, other challenges, like managing expiration dates and packaging waste, could be better addressed by an internal team and process.
Bringing It All In-House
Choosing to assemble variety packs in-house gives companies much more control. While it can require more initial investment, bringing the process in-house increases efficiency, reduces costs compared to using a co-packer, and minimizes waste. In-house assembly also ensures that quality control and expiration date issues are handled efficiently, reducing the risk of recalls.
If they consider in-house assembly options, many producers will stage bagged products in a warehouse until they’re ready for final packaging. This enables a more controlled and efficient process separate from the primary production line.
Considerations for Automation
- Volume: Is there sufficient volume to justify an automated solution?
- Product Variety: How many flavors or products will be included in the variety packs?
- Pack Pattern: Does the pack have a random pattern or a precise, organized arrangement?
- Warehouse Space: Automating the variety pack process in a warehouse is often more efficient, but enough space is needed to accommodate the equipment.
- Expertise: Variety pack lines can be complex. Working with someone with experience setting them up is crucial for optimizing efficiency and avoiding issues.
What Automated Options Are Available for Variety Pack Assembly?
Once a snack producer decides to implement an automated solution to improve efficiency and throughput, they will need to consider the type of setup and level of automation they want. In a typical variety line, operators dump bags from bulk into feeders, which single-file the products onto a conveyor for the next stage of assembly. From there, a producer has a few options depending on their budget, space, and packaging needs.
At BluePrint Automation, we offer three different methods that repurpose mature technologies we have used for automation to create innovative variety pack lines for snack manufacturers.
Method 1: The Count and Batch System with a Drop Chute
This method is ideal for random patterns or "jumble packs" where precise product orientation isn't critical. It's often the simplest and most cost-effective solution.
- Products are fed into feeders and conveyed into separate product lines for each flavor.
- A counting system tallies the products, and when a predetermined batch size is reached, a drop chute opens.
- The batch of products is dropped into a case. These cases move along their own conveyor, stopping at each drop point until the variety case is complete.
- A shaking mechanism helps settle the products within the case to maximize space. A photo eye also ensures the correct number of bags are in each box. The boxes are then sealed and ready to be palletized.
The count and batch system is popular for its simplicity and ability to handle various product types and quantities. It is also ideal for cases where the products do not have a specific orientation requirement. However, it's less suited for applications where products must be precisely arranged or displayed.
Method 2: Robotics
Robotic systems are preferred for complex patterns, store displays, or a high degree of flexibility. While some parts of the line will be similar, the main difference is that robots are used instead of drop chutes, a case packer, or manual laborers to place the bags into a sack machine or directly into a case. This allows for more precise packing and increases speed for high-demand applications.
Using vision guided systems, robots can pick, place, and orient products in any predetermined packing style within the case and handle many different flavors or product types for a sack or case format. Their flexibility lets them quickly adjust to new pack configurations without significant changeover. Robotics also ensure high precision to prevent errors in the bag count or flavor distribution.
Robotics are the most versatile solution but require a more significant initial investment and floor space. However, the benefits of precision, flexibility, and the ability to handle complex packaging requirements often outweigh the costs.
Method 3: A Traditional Case Packer
The traditional case packer is the final automaton method we will discuss. It can pack products in a predetermined pattern and orientation rather than a jumble pack. Case packers have specific areas where each product or flavor is fed, and the products are guided into the case packer through an organized in-feed system. Like the other methods, feeders, conveyors, and other machines support the different processes on the variety pack line for the desired packaging format.
Case packers are a good option for companies with simple variety pack needs. They offer a middle ground between the simplicity of the drop method and the complexity of robotics, but they lack the flexibility to handle more than a few product variations. They are best suited for applications where producers have limited flavors (typically two or three) and require a predictable case pattern for consumers or store displays.
Wrapping Up
Setting up a variety pack line is a strategic decision requiring careful consideration of your needs and resources. By understanding the strengths and limitations of each method, you can choose the optimal solution for your facility. BPA specializes in secondary packaging automation, and a primary advantage of choosing to partner with us is our expertise and experience in setting up variety pack lines.
We have implemented a wide range of solutions incorporating mature technologies to eliminate surprises and challenges that make this particular line design difficult. With careful planning and the right equipment, you can create efficient and profitable variety pack operations that meet customer demand and drive growth. Let’s discuss ways we can add automation to your variety pack assembly.
