kompackt - the customer magazine from meypack

IssUe 1 | 2012

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THE CUSTOMER MAGAZINE FROM MEYPACK

MoRocco – A DeseRt PeARLMeyPAcK RePoRts on MoRocco, tHe MAGHReBIAn

KInGDoM In noRtHWest AFRIcA

2814

A little grain – in a starring roleMeypack supplies a combined end-packaging machine to Reismühle Brunnen

AnugaFoodTec 2012Meypack presents a new tray/lid case packer in cologne

30

Growth MarketWith its tailor-made solutions, Meypack has established itself in the food industry

kompackt 1/2012

Dear Readers,

Around 50 years ago, Meypack got its start in the machine manufacturing business. At that time, the company’s focus was solely on the beverage and canning industries. The machine portfolio and technical innovations were developed to suit these industries. It was a question of packing bottles, jars and cans as fast and economically as possible. However, soon the market started to exhibit much greater product diversity. Other product shapes, formations and materials came on the scene. Product diversification – with the goal of providing consumers with the largest variety of products to meet their individ-ual needs – is the new catch phrase.

In this context, it has paid off for Meypack that it has long been in the enviable position of not only being able to build solid standard machines but also to plan, design and build customised solutions to meet the unique needs of its diverse customers. Consequently, it was a logical step to incorporate and cultivate companies from the food industry into its customer segment. In addition to the beverage industry, we are increasingly serving more customers from the food industry, coming from the most varied areas of this segment. Our machines are particularly well-suited for customers with a broad product spectrum. Devel-oping expertise for the food industry was an extremely extensive task that we approached with a great deal of dedication and continue to do so to this day. The success achieved thus far motivates us even more to continue along this chosen path. Today, Meypack is almost equally active in the beverage andcanning industries as well as in the food industry – worldwide. We are eager to take on further challenging tasks, which we will master and execute. In this current issue of the kompackt, you can read about some of the highlights of our recent activities. And we will be presenting first-rate ideas for the food industry at Meypack’s trade fair stand at this year’s Anuga FoodTec in Cologne. Come visit us and we would be very pleased to discuss them with you.

I hope you enjoy the current issue of the kompackt and that it gives you some new food for thought.

eD I toR I A L 3

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Peter Böckenholt,Managing Partner of Meypack Verpackungs-systemtechnik GmbH

2014 18Engineering: Meypack develops a new paddle chain, which guarantees reliable transport of the products into the packaging machine

Success stories: At Reismühle Brunnen (RMB), products are fed into the machine via a paddle chain and are then pushed out as a row of products

Success stories: With more than 50 years of tradition under its belt, Café Liégeois is an internationally well-known quality coffee roaster, remaining true to its love of coffee

CSM DeutschlandMeypack installs two VP 451’s to pack blocks and slabs of margarine

26

Unilever HungaryAt its production facility in Röszke, Hungary,the fifth Meypack machine goes into operation

22

CosumarMeypack supplies three additional packaging machines plus a PK 110 palletiser to this Moroccan sugar cone producer

12

Growth market – the food industryMeypack rises to the sophisticated challenges of this market segment

30

4 con t en ts

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IMPRInt Publisher:Meypack Verpackungssystemtechnik GmbHIndustriestraße 3D-48301 nottuln-Appelhülsentel.: +49 (0) 2509 - 940Fax: +49 (0) 2509 - [email protected]

Conception, Compilation, Design:FBKB – Agentur für KommunikationLinus-Pauling-Weg 8D-48155 Münstertel.: +49 (0) 251 - 9811990Fax: +49 (0) 251 - [email protected]

Managing Partner: Peter Böckenholt

Photos/Illustrations:Meypack, cosumar, Reismühle Brunnen, café Liégeois, Unilever Hungary, csM Deutschland, Koelnmesse, istockphoto.com, dreamstime.com

Print-run:3,000 copies

Frequency:2 x per year

carbon neutralnatureOffice.com | DE-260-892426

print production

3 Editorial

6 Morocco – a desert pearl Meypack reports on Morocco, the Maghrebian Kingdom in northwest Africa

12 A sweet cone – but not the frozen variety Meypack delivers three more packaging machines as well as a palletiser to Morocco

14 A little grain – in a starring role Meypack supplies a combined VP 451 K sW 60 D end-packaging machine

to Reismühle Brunnen (RMB)

18 For the love of coffee the Belgian company café Liégeois once again places its trust in Meypack technology

20 Multifunctional and ingenious Meypack’s new paddle chain guarantees reliable product transport

– even at very high running speeds

22 It’s in the bag Meypack delivers the fifth machine to Unilever Hungary

26 The baker’s favourite ingredient … csM Deutschland receives two Meypack end-packaging machines

28 Anuga FoodTec 2012 Meypack presents a new tray/lid case packer

30 Food industry Meypack reports on highly complex applications and the extremely diversified product

range in the sophisticated food market and how it rises to these challenges

31 Last but not least

31

31Last but not leastA total of six new employees are starting work at Meypack in early 2012

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Copyright:© 2012 MeypackVerpackungssystemtechnik GmbH

Any reproduction subject to prior approval.the contents do not necessarily reflect the opinion of the publisher in every instance.

For questions about distribution or orders:tel.: +49 (0) 2509 - [email protected]

this issue of the kompackt magazine can be viewed online at www.meypack.de

In Arabic, Morocco means al-Mamlaka al-Maghribīya, “the Western Kingdom.” It is situated in northwest Africa and borders on both the Mediterranean as well as on the Atlantic. the word Maghreb originally meant “the West.” the name Morocco was derived from the name of the former capital Marrakesh in the 16th century.

Morocco – a desert pearl

6 PeoPL e & PL Aces

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Even though the land area is rela-tively small in comparison to other African countries, it does boast

diverse topographical features. The Mediterranean Coast is predominantly characterised by steep cliffs as well as many capes and bays. In the West, the moun-tainous coastal section stretches in a crescent shape to the northwest tip of Africa in the direction of Europe. In contrast, the Atlantic Coast is a flat, smooth, counter-balancing coastline with strong sand movement, making it unsuitable for harbours. Stretching inland there are wide coastal expanses, such as the Sebou Gorge near Kenitra, as well as Casablanca’s expan-sive coastal meseta, or plateau. Further inland, the elevation climbs to around 450 metres above sea level to the central section of the Moroccan Meseta, an

extensive plateau also referred to as the inner meseta or the high plateau of Marrakesh. In the South and East, the meseta is surrounded by the distinctive High and Middle Atlas mountain ranges. Functioning as an important climatic division, the mountain ranges separate the Atlantic/Med-iterranean Morocco from that part of the country influenced by the Sahara. The highest mountain in North Africa is Jbel Toubkal, measuring 4,167 metres. South of this, peripheral desert landscape stretches out, encompassing the Tafilat Basin and the Draa Valley. In Western Sahara along a wide coastal plain, dune-covered sandstone plateaus – which are dis-sected by dried up river beds known as wadis – rise up to a height of 350 metres and are also classed as part of the Sahara.

PeoPL e & PL Aces 7

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in the central meseta and in the Atlas Mountains: In Marrakesh summer temperatures can reach 45 °C while winter temperatures can hover around freez-ing, even accompanied by snow in the mountain regions. South of the Atlas Mountains, the periph-eral Sahara region is subject to an extremely hot, dry desert climate. There is very irregular precipita-tion, making cultivation only possible in oases with irrigation. During the summer months the occasionalsirocco wind blows through – hot and dust-filled coming from the Sahara.

A nation of Berbers and nomads?

Berbers and Arabs comprise the population of Morocco. Approximately 80 % of the inhabitants are Berbers who are predominantly settled farm-ers; only a minority still live as nomads or semi-nomads in remote areas of the Middle Atlas Moun-tains or on the high plateaus in the eastern part of the country. The largest Berber ethnic groups are the Chleuh (language: Taschelhit), the Beraber (lan-guage: Tamazight) and the Rifkabylen (language: Tarifit). The Haratin, the Moroccan Jews as well as the residents of European descent represent the most important ethnic minorities in the country. It can generally be said that the Berbers tend to be more rural while the Arabs are primarily city dwellers. The only large Moroccan city with a Berber majority is Marrakesh.On the whole, the population density in Morocco is very uneven. Two-thirds of the inhabitants live

on approximately one-tenth of the land area in the Northwest or the West. Areas of

climatic extremes

The Moroccan climate transitions from the Mediterranean influenced Northwest of the

country to the Saharan-continental South and Southeast. The northwestern section

experiences hot, dry summers. Temper-atures during the mild, rainy winters

average around 12 °C, although the rainfall tapers off towards the South. Moving into the interior, the moder-ate influence of the ocean drops off considerably, giving way to a char-acteristically continental climate

on approximately one-tenth of the land area in the Northwest or the West. Areas of

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8 PeoPL e & PL Aces

The city of Casablanca with a view of the Hassan II Mosque, one of the

largest mosques in the world

urban concentration are found in the coastal regions in the North and Northwest as well as in the Sebou lowlands.

The official language throughout the country is Arabic. A wide array of Berber languages is spoken by Moroccans of Berber ancestry. French is used throughout the entire country as the language of trade and education. Spanish is also spoken in north-ern Morocco, in Western Sahara and in Sidi Ifni.

Morocco is a member of the United Nations, the Arab League and the World Trade Organisation (WTO).

casablanca – the most important metropolis in the country

The city’s name is derived from Spanish and means “white house.” The Arabian name is “Dar el Beida.” Casablanca lies south of the capital Rabat, directly on the Atlantic Coast. It is the most important trade and industrial centre in Morocco, has the largest harbour in North Africa and is the largest city in Morocco with approximately 3.5 million inhabitants. When the out-lying urban areas are included, Greater Casablanca

is home to around 4 million residents and is the most densely populated city in the country.

Historical records make reference to the Berber settlement of Anfa in the 8th century, its founda-tion walls serving as the base on which the current city was built. In the 18th century, it was re-settled by Arabs under the name Dar el Beida. Spanish merchants also moved there and named the city Casablanca. At the end of the 19th century, many Europeans moved to Casablanca. The nearby phos-phate deposits made the city the most important trading centre; it was built into an economic centre, where numerous colonial buildings and villas were erected. Casablanca maintained its position as an economic hub after the colonial period and is the most important city in the country today. The fish canning industry and nearly half of the remaining Moroccan industry have also set up shop there.

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PeoPL e & PL Aces 9

The Draa Valley in Morocco, a peripheral desert landscape of the Sahara

Over 60 % of the entire Moroccan export business is handled in Casablanca’s harbour. Many of the country’s important companies, such as Cosumar, have their headquarters there.

“Here’s looking at you, kid!”

Casablanca – it isn’t only the largest city in Morocco but also the setting of the famous Hollywood film classic “Casablanca” from 1942, starring Humphrey Bogart and Ingrid Bergman. The film “Casablanca”

was created amidst the backdrop of the Second World War and has become a film classic that still enjoys great popularity today. One quote from Casablanca, Bogart’s famous line

“Here’s looking at you, kid!” is one of the most famous in film-making history. In 2002, the Ameri-can Film Institute chose “Casablanca” as the best USlove story of all time and in 2007, it was selected the third best US film in history.

tea and sugar – the Maghrebian tea culture

The Moroccan national drink is peppermint tea, other-wise known as thé à la menthe or whisky marocain,a combination of Chinese green tea with fresh mint (known as “nana” in Arabic) that is mostly served with a lot of sugar. The art of tea preparation is a ritualised form of tea drinking in Maghrebian countries as well as in northwest African countries such as Morocco, Mauritania, Algeria and Tunisia as well as with the Tuareg people. It is a ritual with an important communicative function and is an integral part of social interaction.

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10 PeoPL e & PL Aces

Official language: Arabic

Capital city: Rabat

Form of government: constitu-

tional monarchy

Head of state: King Mohammed VI

Area: 446,550 km²

Population: 32,360,471 (october 2011)

Population density: 72 people per km²

Currency: Moroccan dirham

Independence: March/April 1956

Time zone: Utc

coUntRy PRoFILe

Kingdom of Morocco

Lighthouse at Cape Spartel, the most northwestern point in Africa at the entrance to the Strait of Gibraltar

Official language: Capital city:

Head of state: Area: 446,550 km²

Kingdom of Morocco

To prepare the beverage, green tea is placed in a pot and cooked for a number of minutes. Thereafter, the tea is strained into another pot, a large amount of sugar – preferably from a sugar cone – is added, and the mixture is then boiled. During the process of re-boiling, the sugar mole-cules hydrolyse, splitting into glucose and fructose, altering the flavour of the tea and making it sweeter. Fresh mint leaves are often added, either during the boiling process in the pot or to the glasses when the tea is being served.

In cafés in Morocco, green tea is served insmall pots which the customer uses to pour into the glass and over the mint leaves and chunks of white sugar.

The sugar needed for this tea preparation, as well as for other purposes, is produced by the local company Cosumar in Morocco and packed with Meypack end-packaging machines.

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PeoPL e & PL Aces 11

the sugar cone is solidly anchored in Moroccan tradition and plays a central role in the daily lives of Moroccans. It is not simply a food product,

but is also a symbol for family, hospitality and religion. the Moroccan company cosumar produces this crystallised product, in

addition to other varieties of sugar.

A sweet cone – but not the frozen variety

In 1929, the company Cosumar was founded in Casablanca by the “Société Nouvelle des Raffineries de Sucre de Saint Louis de Marseille.” Over the years, it has grown into a state-run company

with an annual turnover of nearly 5.8 billion Moroccan dirhams in 2010 (around 520 million Euros). The company employs approximately 2,500 people. In addition to the sugar refinery in Casablanca, Cosumar also owns five sugar beet processing facilities in Doukkala, Gharb, Loukkos, Tadla and Moulouya and two sugar cane processing facilities in Gharb. The company also produces sugar cubes and granulated sugar in addition to the traditional sugar cones.

but is also a symbol for family, hospitality and religion. the Moroccan

addition to other varieties of sugar.

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12 s Ucces s stoR I es

Meypack Representative Morocco:

Walter Mertz HamburgBureau au Maroc10, Rue Iles Caraibes20050 Casablanca (Ain Diab)Morocco

Tel. +212 (0) 522-797929Fax +212 (0) 522-797654 [email protected]

Contact person:Klaus Mertz

cooperation for more than ten years

Back in 2000, Meypack developed a machine to pack sugar cones by positioning them on pads and then wrapping the bundle in shrink film for the production facility in Sidi Bennour. The 2 kg sugar cones are positioned in groups of 6 onto a pad. Two additional cones are then inserted upside down into the formation of 6. The group of 8 is then wrappedin film and shrink-wrapped to create a stable bundle.

The Moroccan company Cosumar, founded in 1929 by the “Société

Nouvelle des Raffineries de Sucre de Saint Louis de Marseille” produces many sugar products. One of them is the sugar cone, a product solidly anchored in Moroccan tradition. The

company employs around 2,500 staff members and has its headquarters in

Casablanca.

Berber woman at a tea ceremony with frish peppermint tea and sugar cone

In 2008, two further packaging machines of the same type were ordered for the newly built facility in Casablanca. Both machines were deliver-ed in Meypack CleanDesign execution. In 2010, three more machines followed: two for the facil-ity in Sidi Bennour and one machine for the Suta production facility Ouled Ayad, a sugar company acquired by Cosumar in 2005.

From the pad to the pallet

Palletising the bundles of sugar cones had been carried out manually at all of the facilities. In May

2011, a Meypack PK 110 palletiser was installed at the facility in Casablanca as part of a pilot project. With a palletising output of two layers per minute, this single palletiser is able to process the bundles emerging from two shrink-wrapping systems. As soon as the new production hall has been completed in Sidi Bennour, this palletiser will be installed there. The factory in Casablanca will then get a Meypack palletiser with a highercapacity of four layers per minute. Eventually,this palletiser will palletise bundles of sugar cones emerging from a total of four shrink-wrappers.

the sugar cone – a product with a history and a tradition

A sugar cone has a rounded upper tip and is made entirely of sugar. While the shape has become very rare on a worldwide scale today, during the 19th and 20th cen-tury it was the most common form of sugar sold due to the production methods of the times. The sugar cone is extremely hard and must be broken into smaller pieces in order to be used for most purposes.

The sugar cone has a permanent place in Moroccan tradition. Associated with the important events in the life of a Moroccan, it is not only served during traditional tea ceremonies but also during other events such as pilgrimages, weddings and births. The sugar is broken into smaller pieces with a special, often decoratively adorned sugar hammer, or occasionally with tongs.

The sugar is broken into smaller pieces with a special, often decoratively

bundles of sugar cones

a rounded upper tip and is made entirely of sugar. While the shape has become very rare on a worldwide

s Ucces s stoR I es 13

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The Swiss company Reismühle Brunnen (RMB) imports rice

products from around the world. The company was founded as a joint stock company in 1956. Since 2004, RMB has been a

division of the Coop Group, with a distinctive identity of its own at

its Brunnen location.

fair & goodtion serving to polish and whiten the rice. To prevent the enormous loss of vitamins and minerals during processing, the raw rice is first soaked in water and then treated with hot steam, causing the nutrients that are being released to diffuse into the endosperm. This process creates parboiled rice (from partially boiled), which retains approximately 80 % of the vitamins and minerals contained in the natural, whole grain brown rice.

The entire production process is accompanied by a number of cleaning steps. These include magnetic separators to remove any metal bits that might have made their way into the batch, sieves to sort out left over husks, straw, or other grains of cereal, as well as

For more than half of the world’s population, rice is the main staple food. there are more than 120,000

types of rice worldwide. the swiss company Reismühle Brunnen (RMB) has been importing rice products from

around the world for more than 50 years.

A little grain – in a starring role

After undergoing special moni-toring to determine if the incom-ing raw rice is of the agreed

quality and free from pests or mould, the husks are removed in a rice mill. What remains is the whole, natural grain consisting of the endosperm, germ and the encompassing bran. This stage is referred to as hulled rice or brown rice. Some of this natural rice or whole grain rice makes it onto the store shelves. Furthermilling removes the bran and the germ from the hulled rice. In this form, the rice is referred to as white rice or milled rice. The raw rice remaining after mill-ing is smoothed through a friction polishing process. This is carried out either dry or with water by forcing the grains against each other, with the resulting fric-

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de-stoners to sort out any foreign particles the size of a rice grain, such as little stones or weed seeds. Lastly, a light sensor carries out optical monitoring to identify and sort out dark grains or those of the wrong colour.

switzerland’s no. 1 rice importer

The Swiss company Reismühle Brunnen (RMB) imports rice products from around the world. The company was founded as a joint stock company in 1956. Since 2004, RMB has been a division of the Coop Group, with a distinctive identity of its own at its Brunnen location. RMB employs a workforce of 18.

The company’s location in Brunnen, on the banks of Lake Lucerne, is very central and excellent in

logistical terms. RMB imports rice from all over the world, mostly using ecologically responsible forms of trans-port such by ship or rail. The rice processing is carried out by modern equipment

that ensures gentle product handling. Working in two

shifts, RMB achieves a produc-tion capacity of approximately

12,000 tonnes of rice, of which 10,000 tonnes are con-venience products. Through gentle processing, a high yield of about 82 % is generated. Sorting and milling the rice generates by-products amounting to about 18 % of weight, which are transformed into high-quality animal fodder.

The Swiss company Reismühle Brunnen (RMB) imports rice products from around the world. The company was founded as a joint stock company in 1956. Since 2004, RMB has been a division of the Coop Group, with a distinctive identity of its own at its Brunnen location. RMB employs a workforce of 18.

The company’s location in Brunnen, on the banks of Lake Lucerne, is very central and excellent in

logistical terms. RMB imports

that ensures gentle product handling. Working in two

shifts, RMB achieves a produc-tion capacity of approximately

Meypack Representative Switzerland:

Chromos AGNiederhaslistrasse 128157 DielsdorfSwitzerland


Contact person:Rolf Knaus


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The product range produced in Brunnen covers about 40 types of rice with more than 300 forms of packaging in a variety of shapes and designs.

Diligence and reliability – also during end-packaging

In autumn 2010, RMB invested in a combined Meypack VP 451 K SW 60 D packaging ma-chine that was commissioned in May 2011. The machine packs bags and folding boxes of rice in a total of 14 formations into trays with or with-out film, or alternatively in wrap-around cases. The machine packs rice in bags ranging from 0.5 kg to 2 kg and in folding boxes from 0.25 kg to 1 kg.

The bags and folding boxes first enter the case section of the Meypack machine in continuous motion in single file with the short side leading;

All in a row:Products are fed in via a paddle chain then pushed out row by row

they are then brought into a standing

position in the paddle chain. The desired formation is created at the end of the infeed conveyor, where the products are pushed over row by row. Simultaneously, a flat card-board blank is removed from the blank maga-zine and positioned directly underneath the grouping station. The product formation and the blank are guided together into the lateral folding aids of the lowering station. During this step, the blank is folded very tightly around the product formation, then glued and pressed.In the final film section, trays can also be wrappedin film and shrunk. If film is not desired, the trays just pass through this section.

The machine output is dependent upon the type of packaging and the upstream machine.

the clinchers: Machine design and format flexibility

The determining factors for the purchase of this Meypack machine were in particular the com-pact and open design of the machine as well as

“In my opinion, Meypack is the ideal choice in the area of

secondary packaging. The critical factors for

us were the compact machine design, format flexibility and the tech-

nically sophisticated execution.”

Gerhard Marty, Head of Production

The product range produced in Brunnen covers about 40 types of rice with more than 300 forms of packaging in a variety of shapes and

they are then brought into a standing

position in the paddle chain. The desired formation is created at the end of the infeed conveyor, where the products are pushed over row by row. Simultaneously, a flat card-board blank is removed from the blank maga-

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Basmati Rice SaladServes 4

Ingredients1 red pepper

1 yellow pepper

200 g green peas, cooked al dente

300 g Basmati rice

8 black olives, pitted

cayenne pepper

mixed leaf lettuce

sesame seeds (lightly toasted in the oven)

Sauce:

3 TB cider, white wine or red wine vinegar

2 TB vegetable stock

1 TB soy sauce

1 Tsp Dijon mustard

5 TB olive oil, extra virgin

freshly ground black pepper

herbed salt

PreparationHalve the two peppers, remove the stalk and the seed

s and dice the halves.

Boil the rice in 900 ml water with one teaspoon of salt added. Boil for fi ve

minutes, and then simmer for 15 minutes over low heat. Check the rice frequently

to see whether it is soft enough.

Add the peppers, peas, olives and rice to the sauce

and add cayenne pepper to taste.

Arrange the rice salad on the mixed leaf lettuce and sprin

kle the sesame seeds on top.

The sesame seeds will be even tastier if they are lightly roasted in the

oven fi rst.

All bundled up: Lowering a product formation onto a wrap-around blank in 4 x 3 formation

meters that can be automatically changed. Given the diversity of products that RMB packs, it was important to find a highly flexible solu-tion to enable not only fast but also simple for-mat changeovers that can be carried out by RMB’s operating staff.

Sustainability and energy efficiency are very important topics at Reismühle – solar energy has been in use since 2011, a reason why the engineering department places a high priority on servo motors. The advantageous energybalance of the Meypack machinewas another aspect that gave the nod to the Meypack solution.

the technical features with respect to the format changeovers and energy efficiency. The machine is not only compact but also constructed in Meypack CleanDesign execution. Thanks to the open design, cleaning the machine with compressed air as well as mechanically is extremely easy. Abstaining from the use of water – something that is an absolute necessity when processing rice – poses no problem either. Given that hygiene is also an important criterion for RMB and stringent food and hygiene regulations must be strictly adhered to, this proved to be another plus point for Meypack.

Another decision criterion that spoke for Meypack were the fast modular change systems with para-


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The Belgian family business was founded in 1955 and is run today by Charles Liégeois’s two sons, Michel and Benoît, employing around 100

people. Today, with more than 50 years of tradition under its belt, Café Liégeois is an internationally well�known quality

coffee roaster, remaining true to its love of coffee. The headquarters

of Café Liégeois are located in the Belgian town of Battice in the

region of Liège.

is an internationally well known quality coffee roaster, remaining true to its

love of coffee. The headquarters of Café Liégeois are located in the

Belgian town of Battice in the region of Liège.

coffee – it is lifestyle, passion, indulgence, tradition. coffee is the cosy cappuccino in a café or at home, but it is also the “latte to go” for on the road. coffee is undisputedly the favourite beverage of Germans and one of the most popular beverages in europe.

Coffee is Germany’s favourite beverage: Germans drink around 150 litres per year –

and with that more than water or beer. That is the equivalent of three to four cups a day. In 2008, a total of approximately 400,000 tons of roasted coffee and around 12,200 tons of instant coffee were sold throughout Germany, corresponding to 519,000 tons of green coffee. The highest coffee consumption in the world is in Finland, where 11.5 kilograms or 1,300 cups of coffee are consumed per person per year. The Belgians follow with 9.5 kilograms of coffee per person, with the Norwe-gians, Danes and Swedes close behind at 9 kilo-grams. In Switzerland, Germany and the Nether-lands, per capita consumption comes in at a little more than 6 kilograms.

café Liégeois – a company combining tradition with passion

The creation of Café Liégeois can be attributed to Charles Liégeois’s passion for coffee. The Belgian family business was founded in 1955 and is run today by Charles’s two sons, Michel and Benoît, employing around 100 people. Today, with more than 50 years of tradition under its belt, Café Liégeois is an interna-tionally well-known quality coffee roaster, remaining true to its love of coffee.

Roasting and sales of coffee account for 60 % of Café Liégeois’s business activities. To round out its reper-toire, it also packages sugar and milk. Parallel to this, the company provides logistic and customer services for the installation and maintenance of coffee and espresso machines for professional clients and private

A perfect fi t: Placing the pre-formed, inner-lying lid into the tray inside the lowering station

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For the love of coffee

“We can act, so we should act!”

customers, in addition to delivering a wide range of products such as snacks, beverages, cleaning products and dishes that are required by business clients and public institutions.

Café Liégeois is headquar-tered in the Belgian town of Battice in the region of Liège. Administration, production facilities and the warehouse are located there, covering an area of around 9,000 m².

Mano Mano – Hand in Hand

Café Liégeois is a coffee roaster. Thus, it goes without saying that the company is in contact with countries in Middle and South America, Africa and Asia. Working in close cooperation with Terre Solidaire and the Max Havelaar brand, Café Liégeois devel-oped the Fair Trade product line Mano Mano and brought it onto the market. The name stands for the will to work with the farmers in Chiapas in South-east Mexico hand in hand.

The objective of Mano Mano is to guarantee the producers a minimum price regardless of the current market price, according to the princi-ples of Fair Trade. This guarantees that the pro-ducers earn a correct and constant minimum income. By doing this, Café Liégeois makes a clear statement and even reinvests € 0.10 into the province of Chiapas for every package of Chiapas Coffee Pads sold in the supermarket.

Meypack packaging machines in triplicate

At the Belgian production facility in Battice, three Meypack ma-chines are in operation packing pouches of coffee pads for Café Liégeois. Two of the machines are VP 451 K wrap-around case packers that pack pouches of 18 and of 36 pads

in 5 x 2 and 5 x 3 formations into wrap-around cases. A new Meypack VP 452 packs the pouches of coffee pads in trays with lids. The 4-sided lid is inserted into the tray and secured with adhesive. It is also pos-sible for this machine to pack in wrap-around cases. Pouches of 18 and 36 pads are packed in 5 x 1 and 5 x 2 for-mations. The pouches with 48 pads or respectively 56 pads are packed in 5 x 2 formations and only in wrap-around cases. While the two Meypack VP 451 K’s can pack 25 pouches per minute, the VP 452 processes 35 pouches per minute.

To be able to meet the growing demands posed by today’s supermarkets, the third machine was designed to be able to pack in wrap-around cases with Easy-Opening perforations as well as in trays with lids.

Meypack Representative Belgium:

Bipack bvbaRollegemsestraat 138510 Bellegem (Kortrijk)Belgium


Contact person:Christian Holcomb

Café Liégeois is a coffee roaster. Thus, it goes without saying that the company is in contact with countries in Middle and South America, Africa and Asia. Working in close cooperation with Terre Solidaire and the Max Havelaar brand, Café Liégeois devel-oped the Fair Trade product line Mano Mano and brought it onto the market. The name stands for the will to work with the farmers in Chiapas in South-east Mexico hand in hand.

The objective of Mano Mano is to guarantee the producers a minimum price regardless of the current market price, according to the princi-ples of Fair Trade. This guarantees that the pro-ducers earn a correct and constant minimum

At the Belgian production facility in Battice, three Meypack ma-chines are in operation packing pouches of coffee pads for Café Liégeois. Two of the machines are VP 451 K wrap-around case packers that pack pouches of 18 and of 36 pads

The origins of coffee can be traced

to the Ethiopian region of Kaffa. In the highlands there, the plant

species caffea arabica has its origins. It is the mother of all of

today’s various coffee plants worldwide.

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Multifunctional and ingenious: Meypack’s new paddle chainGrowing demands for greater robustness and fl exibility were decisive in the development of the new Meypack paddle chain, which guarantees reliable transport of the products into the packaging machine – even at very high running speeds of up to 300 products per minute.

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Modern packaging ma-chines are characterised on the one hand

by increasingly high cycling rates and on the other by the largest possible flexibility and the easiest handling when it comes to format changeovers. These are demands placed on the packaging industry by today’s international corporations. Meypack’s new paddle chain was developed to fulfill the increased demands for ever higher capacities. It is a consistent further development of the proven chain system.

optimal curve shape for fast and safe transport

The mechanical form of the paddle chain has been completely overhauled and adapted to ensure that the products enter the paddle chain at the optimal infeed angle. In the new system, the products always enter lying flat and are then brought into the desired position, in which they are then packed.

The infeed angle of the paddle chain is optimally set according to the product to be packaged. This ensures fast and reliable erection of the product in the paddle chain. Each paddle in the new paddle chain is individually controlled, enabling a strong and precisely guided paddle situation when the products are being pushed out of the paddle chain.

Use of the new paddle chain in both the VP 400 series and the VP 500 series Fast and reliable erection of the accumulated products thanks to the optimised chain curve Robust and precise paddle situation when the products are being pushed out of the paddle chain, thanks to individually controlled paddles Innovative change system for fast and easy format changeovers emptying the paddle chain by pushing the products out, or alternatively by using either a gripper system or a suction system

sUMMARy

Emptying the paddle chain can be achieved by pushing the products out, or alternatively by using either a gripper system or a suction system.

not simply a quick change artist

A particular highlight of the new paddle chain is the possibility for a fast and easy change. The innovative change system encompasses the entire paddle chain, making it possible to exchange the chain in one fell swoop. The new paddle chain is used in the packaging machines of the VP 400 Series and the VP 500 Series. This paddle chain is especially well-suited for light, narrow products like pouch packages, such as soup pouches with sealed edges. It is also well-suited for products like folding boxes, stand-up pouches, bags or shaped containers.

Paddle chain with product specific product cycling via a star wheel system

Side view of a dual cluster paddle chain for high-speed applications, either for pouches or folding boxes

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It’s in the bagIn the Hungarian village of Röszke, located south of Budapest near the serbian border, Unilever Hungary uses Meypack VP 453 case packers to pack pouches – an up-to-date, sophisticated technical end-packaging solution.


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In Röszke, Unilever Hungary produces food products for a total of 17 European countries, predominantly for Hungary,

Austria, Poland and the Czech Republic.

The new Meypack VP 453 case packer is now the fifth Meypack machine for Unilever Hungary. Three of the machines pack Doypacks, 4-sealed-edge pouches as well as double compartment (powder + baking bag) pouches in display trays with lids partially inserted and partially applied to the outside of the tray. The machine has two parallel infeed conveyors, enabling the trays to be filled in an alternating fashion from two sides. The products enter the packaging machine lying flat and are each individually turned by a turning unit in such a way that the bottom edge leads and the “face” of the pouch faces upward. The individual pouches are then cycled into a stacking shaft that can receive up

to seven products on each latch. The latches open at lightning speed when the stacks of pouches are being trans-ferred onto a metal plate below, which is lowered in a controlled manner. A cross pusher pushes the stack of products into a compartment in a rack located in front. This process is repeated until the desired number of products has been reached, whereby the rack is

infeed conveyors, enabling the trays to be filled in an alternating fashion from two sides. The products enter the packaging machine lying flat and are each individually turned by a turning unit in such a way that the bottom edge leads and the “face” of the pouch faces upward. The individual pouches are then cycled into a stacking shaft that can receive up

A cross pusher pushes the stack of products into a compartment in a rack located in front. This process is repeated until the desired number of products has been reached, whereby the rack is


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lowered one level at a time along with each product stack. The rack has a total of five com-partments and can yield a maximum number of 35 products per tray. Once the rack has been filled and then lowered, a second cross pusher simultaneously transfers all product stacks to a pivoting stacking shaft. The pivoting shaft also has individual compartments that are, however, flex-ible. Once all of product stacks have been received, they are pressed together to create a tight formation that can be guided safely and precisely. The pivot-ing stacking shaft pivots 90 ° so that the products are then standing upright, close together side by side. The stacking shaft then moves upward where the formation is pushed by a cross pusher out of the shaft and placed onto a tray blank. The tray blank and product formation are lowered into the cycling chain, forming the tray. The tray filled with prod-ucts is glued and pressed and then transported into the pre-formed lid. The lid is generally positioned on the outside of the tray. However, on the long side of the tray, the lid is partially inserted into the tray and secured with adhesive points to prevent slippage. The lid securing points serve as a modern packaging solution that gives the packaging stabil-ity and the possibility of it being quickly and easily opened at the point of sale. The lid is affixed with two glue points but is easy to open manually.

The machine can process diverse formations that are dependent upon the respective sizes of the pouches. The pouch width and length play a role as does the thickness of the pouch, which varies

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In the Hungarian village of Röszke, Unilever Hungary produces food

products for a total of 17 European countries, predominantly for

Hungary, Austria, Poland and the Czech Republic. The production

facility in Röszke is located south of Budapest, near the Serbian border.

lowered one level at a time along with each product stack. The rack has a total of five com-partments and can yield a maximum number of 35 products per tray. Once the rack has been filled and then lowered, a second cross


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A special form of pouch packaging that is particularly popular with consumers is the sealed pouch. This pouch is not only easy to handle and space saving but is also a hygienically safe form of food packaging. In particular, powdery products such as instant soups or liquid products like dressings are packed safely and in a space-saving form in these pouches. The sealed pouches are avail-able in a variety of forms: with or without stand-up bottoms as well as the option of a re-sealable closure. The most common varia-tions of the sealed pouches are the flat pouch, the stand-up pouch, the double chamber pouch and the bottom gusseted pouch.

In line with Unilever’s Compass strategy for sustain-ability, which includes doubling its business while halving the environmental footprint of its products, this system solution has definite advantages. These include the utilisation of servo motors instead of pneumatics, with an added bonus that this optimised servo controller solution reduces electricity consumption. Furthermore, con-tinuous, positively controlled movement of the prod-ucts through the system allows little opportunity for the powdery product content to settle and create bulges in the pouches. As a result, this packaging solu-tion guarantees higher capacity utilisation of the trays of around 10 to 15 %, reducing the need for corrugated cardboard and improving product transport efficiency, thereby contributing to lower CO2 emissions.

depending upon the content. In addition, double chamber pouches can also be processed. The change-over to different tray formats takes place nearly tool-free. Only the product-specific parts need to be changed.

Unilever – successful with well-known brands from the food industry

As one of the largest producers of food products, Unilever produces and sells food that makes healthyeating taste good, easy to achieve and affordable. Throughout the entire production process, begin-ning with the procurement of raw materials, con-tinuing through the production process on to the delivery of the final product, Unilever pays close attention to maintaining strict quality and hygien-ic standards. One of Unilever’s most well-known brands in the food area is Knorr. Knorr products are among the world’s most successful consumer goods. Already back in the 50’s and 60’s of the last century, “Knorr” became synonymous for quick and delicious soups and a trailblazer in the area of convenience foods. Today, Knorr products are simply permanent fixtures in the kitchens of mil-lions of consumers – serving as valuable helpers in such forms as mixes for meals or salad dressings, as soups, sauces or quick ready meals.

For a majority of its product portfolio, Knorr relies on pouch packaging, and not just in Hungary.

Pouch packaging – practical but fragile and a real challenge for the end-packaging industry

The challenge of packing pouches lies in the “instabil-ity” of the product – especially in the case of double chamber pouches. The packaging material used ex-hibits a low degree of stability, which manifests itself in pouches without defined, recurring dimensions, making processing more difficult. In contrast to tins or jars, for example, various types of contents can have a strong impact on the reaction and dimensions of the primary pouch packaging.

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Step by step: Product fl ow through the Meypack VP 453

case packer

A special form of pouch packaging that is particularly popular with consumers is the sealed pouch. This pouch is not only easy to handle

closure. The most common varia-tions of the sealed pouches are the flat pouch, the stand-up pouch, the double chamber pouch and the bottom gusseted pouch.


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Special marga-rines andspecial

fats are among the most important raw materials in the production of fine baked goods. Without these ingredients it would be impossible to produce such a wide array of baked goods in terms of taste, appearance and function-ality. During today’s production processes for baked goods, the plant oils and fats used have been created to contain precisely calculated proportions of combined fats, which serve to fulfill the needs of the special margarine used later in the produc-tion process. Through the composition and mixing ratios of different fats and oils as well as their derivatives, different consistencies, melting points and creaminess can be attained. The oils and fats

used include canola/rapeseed oil, sunflower oil, palm oil and coconut fat.

For the baking industry, the melting point is of great importance. Furthermore, the fatty

acids play an important role in both the con-sistency and firmness of the fat. One differen-

tiates essentially between cream margarine for fillings and batters, baking margarine – other-

wise known as Danish pastry margarine – as well as puff-pastry margarine. All three types of mar-

garine are available in different levels of quality and there are consequently “Gold Brands,” which

csM Deutschland is the leading supplier of prod-ucts for artisan and industrial producers as well as industrial consumers of baked goods in the German market. the product range includes, among many other things, special margarines that needed to have particularly “soft” handling in the end-packaging.

Thebaker’s favouriteingredient …

pecial marga-

such a wide array of baked goods in terms of taste, appearance and function-

acids play an important role in both the con-sistency and firmness of the fat. One differen-

tiates essentially between cream margarine for fillings and batters, baking margarine – other-

wise known as Danish pastry margarine – as well

derivatives, different consistencies, melting points and creaminess can be attained. The oils and fats


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particularly malleable. For the production of Danish pastry dough using machines, CSM offers slabs of special Danish pastry margarine that are extremely easy to use. In addition to slabs of margarine, the com-pany also produces blocks of margarine. Blocks of margarine, such as Meister Goldzieh, also come as puff-pastry margarine and are thus optimal for producing flaky puff-pastry. In contrast, the product Grand Patissier Creme is perfect to use when making creams and dough. This margarine guarantees a high degree of air absorption, which in turn enables the pastry to expand to a large volume.

Blocks and slabs safely packed

Meypack installed two VP 451 wrap-around case packers to pack blocks and slabs of margarine into wrap-around cases at CSM Deutschland. The machines have been designed to ensure gentle handling of the products during processing, given that the blocks and slabs of margarine are not yet completely firm after they have left the extrusion unit. Furthermore, the product transport is extreme-ly gentle in order to prevent the flaps of the wrap-ping material (aluminium, HDPE, PP, PE or paper) from opening or creasing. The margarine blocks are packed in two layers while the margarine slabs are packed in layers of five. The second machine can pack wrap-around cases with flush-lying side flaps and overlapping side flaps. The machines are equipped with turn-ing stations that turn the product formations either lengthwise or crosswise after they have exited the grouping station – depending upon the desired product direction within the case. Both machines were delivered in stainless steel and CleanDesign exe-cutions – aspects that were very important to the customer because product hygiene receives a very high priority at CSM.

CSM Deutschland is the leading supplier of products for artisan and

industrial producers as well as industrial consumers of baked goods in the German market. The

product range includes, among many other things, special margarines such as cream margarines for fillings and

batters, baking margarine -otherwise known as Danish

pastry margarine - as well as puff�pastry margarine.

are of a partic-ularly high qual-ity due to the optimal compo-sition of raw materials and in-

gredients that re-main highly stabile

during the baking process.

csM – a leader when it comes to special margarines

For the baked goods industry, special margarines are portioned into blocks and slabs, and then packed. In the northern German city of Delmenhorst, CSM Deutschland produces many products under the brand MeisterMarken, including its “Gold” puff-pastry mar-garine in slab form for the production of laminated pastry dough such as puff-pastry dough. Thanks to its high melting point, puff-pastry margarine is

Precise: Controlled product cross pusher with integrated product centering on the loading plate before stacking

Margarine was developed by

the French chemist Mège-Mouriès in

1869 as a response to a reward offered by

Napoleon III for a cheap alternative to butter.

Mège-Mouriès created margarine out of a

mixture of beef tallow and skim milk.

ping material (aluminium, HDPE, PP, PE or paper) from opening or creasing. The margarine blocks are packed in two layers while the margarine slabs are packed in layers of five. The second machine can pack wrap-around

the product formations either lengthwise or crosswise after they have exited the grouping station – depending upon the desired product direction within the case. Both machines were delivered in stainless steel and CleanDesign exe-cutions – aspects that were very important to the customer because product hygiene receives a very

optimal compo-sition of raw materials and in-

gredients that re-main highly stabile

during the baking process.


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The Anuga FoodTec, international trade fair for food and bev-erage technology, is set to be

very visionary and future-oriented this year. Trends and innovations for the coming years from both food and beverage producers as well as from packaging specialists are the focus of the world’s most important trade fair for food and beverage technology, running from March 27th to 30th, 2012 in Cologne.

With this packaging machine designed for a sophisticated dairy-food application, Meypack presents an array of ground-breaking concepts – concepts that will provide interesting stimuli and perspectives for other customers and branches.

At the Anuga Foodtec in cologne, Meypack exhibits a VP 453 case packer – built in stainless steel in accor- dance to the cleanDesign construction Principle – to process plastic containers of butter by packing them in trays with lids. the Anuga Foodtec is the event where the food industry gets together.

At the Anuga Foodtec in cologne, Meypack exhibits a VP 453 case packer – built in stainless steel in accor- dance to the cleanDesign construction Principle – to process plastic containers of butter by packing them in trays with lids. the Anuga

Anuga FoodTec 2012: Meypack presents new tray/lid case packer

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Hygiene and gentle product handling during packaging – the most important factors in the production process

The Meypack VP 453 on exhibit was built entirely of stainless steel according to the CleanDesign Construction Principle. Optimal accessibility, easy and thorough cleaning as well as the machine’s high level of flexibility were convincing arguments for the customer to order two identical tray/lid case packers from Meypack. These were all important criteria, given that the stacking stations will be located in wet areas of production while the packaging machines will be in dry production areas.

Both machines pack rectangular plastic contain-ers of 250 g, 500 g and 1,000 g in trays with lids. The unique lid is inserted into the short side of the tray while the longer sides of the lid are glued to the outside of the tray. The plastic containers have a slightly conical shape and are sealed with a plastic lid on top. One challenge of the project was to transport the containers without pressureand to pack them in a gentle way for two impor-tant reasons: On the one hand, the lids can easily come off if there is even the flightest bit of pressure exerted; on the other hand, the product is still in a fluid state at the time of packaging and can thus easily swash onto the inside of the lid.

The plastic containers enter the stacking station in two lanes. Inside the stacking station, one row of products per lane is created, which is then lowered into the stacking shaft. The procedure is repeated until the desired number of layers has been reached. From the stacking shaft, the com-plete multi-layered rows of products are pushed – alternately from the left and the right sides – onto an intermediate table. This is repeated until the desired number of product rows has been created. The subsequent grouping is carried out by a servo motorised finger grouping system and a

servo motorised cross pusher. The cross pusher stands out due to its extremely gentle product handling, in which only the very bottom contain-ers in the formation are touched in a few places and at no time is there any pressure exerted on the lid – a special feature of this machine.

one of the machines live in action at Meypack’s trade fair stand

The machine on display features a number of highlights that are of particular importance for the food industry. In addition to the optimal accessibility, the CleanDesign execution and the gentle product handling technology, the machine is extremely flexible and can also be used to create wrap-around cases with external top flaps. The format changes are also fast and easy to manage. As a result, a format changeover can be completed within a maximum of 30 minutes by just one operator.

This isn’t the first project for this customer: Over the past years, three VP 451 case packers in CleanDesign execution have been commissioned and a further stainless steel VP 531 machine for a high-speed application is currently in the works.

Anuga FoodTec 2012: Meypack presents new tray/lid case packer

e X H IB I t Ion s 29

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When a company is particu-larly successful in a market, an area or a product cate-

gory, this is usually reflected by continuous growth over a long period of time. And this growth is what Meypack has recorded over years in the discerning food segment. For decades, Meypack was one of the leading German packaging machine manufacturers for the beverage and canning industries in the end-

packaging area and it is well established and well-known in this market segment. And still

today, machine systems are

being built for the beverage industry and sold to domestic and international customers. Parallel to this, activity in the food market has been developing very positively since 2005. Meypack has developed a foothold in this sophisticated market segment, proven by a large number of successful proj-ects that Meypack can already reflect back upon and customers who have ordered machines with Meypack to expand existing facilities or to start up new produc-tion locations.

“The objective was to supplement the portfolio of machine applications in a logical and sensible manner to secure our long term stable growth. For this reason, we have been consistently expanding our product and service range to meet the needs of the food industry as well and developing packaging appli-cations for the food and non-food areas since 2005,” explains Klaus M. Vogel, Director of Export Sales and Marketing at Meypack.

The challenges that present themselves when one enters a new market were characterised in our case by new product manufacturing processes. As a result, not only

the line capacities but also the shapes and specific characteristics of the products to be packed, the materials used, local conditions such as temperature and

humidity in the production facil-ities or difficult to define

product tolerances all pose real challenges

to be mastered. Furthermore, the strict hygienic

regulations in food production facilities as

well as the corresponding sophis-ticated project specifications, the extremely specific cleaning processes and the demands for flexibly designed machines were topics that the Meypack planners and engineers successfully addressed.

Today, Meypack is almost equally active in the beverage and canning industries as in the food and non-food industries – and in the meantime worldwide.

The food industry – the growth segment for MeypackHighly complex applications, extremely diversifi ed products and the highest require-ments for hygiene in the production process – those are just some of the key points that make the food market particularly challenging and sophisticated. It is in this market segment that Meypack has established itself as a customised machine manufacturer offering tailor-made solutions for its customers.

specific characteristics

packaging area and it is well established and well-known in this market segment. And still

today, machine systems are

product tolerances all

being built for the beverage industry

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A total of six new employees are starting work at Meypack in early 2012 –four of them are former apprentices from a diverse range of apprenticeship programs

Committed to personnel development

they’re everywhere, everyone’s talking about them – these QR codes. But what are they actually and how do they work?

QR stands for quick response. With the help of these codes, smartphones and PDAs (personal digital assistants) that are equipped with cameras can call up, save or further process information contained in these codes. QR Codes are different from the previous 2D-barcodes because they can save both vertical and horizontal information and therefore can contain a greater quantity of data. A QR Code can contain information such as internet addresses, telephone numbers, text messages, links, texts or electronic name cards.

How do they work?The user requires a QR Code reader app on his or her smartphone or PDA, which

QR Codes – now also in the kompackt

can be installed for free. The app is then activated and scans the QR Code. Within a few seconds, the QR Code is analysed and the coded link, or respectively the desired website, is opened by a browser.

Why does Meypack use QR Codes in the kompackt?Meypack utilises QR Codes primarily to save links to websites. With the help of the QR Codes, the links guide the user to special sites on the Meypack website that have additional perti-nent information (machine informa-tion, service topics as well as videos and photo galleries) or also links to external websites that can be easily called up by the user. By incor-

porating QR Codes, Meypack combines offline and online content in a simple way. Furthermore, scanning a QR Code is much easier than typing in a complex internet address. In the upcoming issues of Meypack’s kompackt, QR Codes will be easy to find

with the icon. The kompackt wishes all its readers lots of enjoyment when trying them out.

Dates 2012

March 27th to 30th, 2012 Anuga FoodTec 2012 Cologne, Germany Hall 6, Stand B60/C61

September 25th to 27th, 2012 FachPack 2012 Nuremberg, Germany

After completing her apprenticeship, Mareike Dresemann will be working as an in-house electronics technician for electri-cal installations on customised machines, while Lukas Hengemühle will be sharing responsibilities for installing and commis-sioning electrical machines on-site for customers in Germany and abroad. As a trained mechatronics technician, Florian König commissions palletisers and customised machines both in-house

and on-site at the customer. Another grad-uate is Marius Wies, who is responsible for the assembly of the entire machine at Meypack’s production facility in Nottuln as well as for the installation of the ma-chine on-site at the customer. Since February 2012, Florian Springeneer has been working as a mechanical engineer designing Meypack’s packaging machines in the engineering department. He holds a Bachelor of Engineering degree. Com-

petent support will also be provided by Ilhan Caner, who has a degree in electri-cal engineering. He will build the control systems for the case packers, install them and then conduct testing on the machines.

The kompackt wishes all of the new col-leagues a successful start at Meypack.

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Meypack Verpackungssystemtechnik GmbH Industriestraße 3 · D-48301 nottuln-Appelhülsen · tel.: +49 (0) 2509 - 940 · Fax: +49 (0) 2509 - 948190 · [email protected]

www.meypack.de

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kompackt - the customer magazine from meypack