GeconaTEC ® GmbH
March 2008
Complete technology for production of pleasing products projects, constructions, lines and equipment, packaging systems
2008
Hall 2, Stand C 05 PROFILE GeconaTEC® GmbH GeconaTEC GmbH is an engineering company acting as a general contractor for the design, delivery and cons- Business partner from GeconaTEC GmbH: truction of complex systems and entire plants for food processing and packaging. • Aasted Mikroverk
It always uses state-of-the-art and high-performance • Franz Haas Waffel- und technologies supplied by famous European manufactur- Keksanlagen-Industrie GmbH ers. GeconaTEC’s overriding aim is to enable high-quality products to be marketed with the help of the latest • Bosch Sigpack Systems AG processing techniques and packaging technologies. • Teepack Spezialmaschinen GmbH & Co. KG GeconaTEC is a one-stop supplier of turnkey plants – • Hosokawa ter Braak meaning the entire process from planning, fi nancing, production, delivery, assembly and start-up is centrally • Hosokawa Bepex managed and controlled by GeconaTEC. Moreover, all • Hosokawa Kreuter engineering systems are planned and installed by specia- lists from the company GeconaPACK. • Petzholdt Heidenauer Maschinen -und Anlagenbau International GmbH Alongside project management, GeconaTEC also offers its customers a wide range of services such as production • AZO GmbH & Co. KG supervision, preventive maintenance, spares procurement • F.B. Lehmann Maschinenfabrik GmbH and staff training. and others
2 Bene ts of GeconaTEC for the execution of contracts, nancing an transportation SERVICES GeconaTEC – a dependable partner
GeconaTEC is a reliable partner when it comes to technical consulting, bid submission, contract preparation and the implementation of signed contracts.
GeconaTEC has been attested as a company that is prudently managed, doesn’t overstretch itself, and discharges its obligations punctually and conscientiously.
In connection with large-scale projects such as the acquisition of entire plants and production lines to expand or update manufacturing, loans are frequently indispensable.
GeconaTEC therefore works closely together with two major German banks. Consequently, GeconaTEC can also offer Hermes credit fi nancing, allowing both inter-bank loans and under certain circumstances direct loans to the client. GeconaTEC can take charge of the application, draw up the documents required, and actively support planned fi nancing projects. Guarantees (including payment guarantees, advance payment guarantees and performance bonds) can be provided in line with the client’s requirements.
GeconaTEC also has experience in handling credits in export transactions. It promptly draws up, coordinates and obtains the necessary documents depending on the conditions governing the letter of credit.
When building complete plants, GeconaTEC collaborates with proven suppliers manufacturing state-of-the-art equipment to a high level of quality. Working on the basis of the delivery spe- cifi cations, technologies and delivery deadlines contractually agreed with its foreign partners, GeconaTEC concludes suitable delivery contracts with its suppliers with a view to integration within the overall project.
3 SERVICES
GeconaTEC constantly monitors compliance with contractual conditions. It works closely with its partners in the production phase, maintains personal contact, discusses solutions, keeps track of production progress, and conducts joint tests on key machinery.
The presence of GeconaTEC’s clients is especially welcome during test runs. Before informing the client that an order is ready for dispatch, GeconaTEC has the equipment examined on the supplier’s premises and certifi ed for compliance with the contract specifi cation as well as in terms of quality and quantity by an international inspectorate.
It then has the equipment transported by a logistics contractor with many years’ experience of deliveries to the CIS (especially Russia) which maintains an offi ce in Moscow, and which remains constantly in touch with the freight forwarders on the ground.
GeconaTEC also works together with the transport company to optimize transport operations by maximizing the use of available lorry capacity. It has the equipment collected from the suppliers, collates partial deliveries, and helps its suppliers draw up the necessary transport documents.
Depending on the size of the goods to be transported, GeconaTEC orders special lorries which arrive punctually along with any offi cial permission required for the planned route.
In addition, GeconaTEC keeps tabs on deliveries until they reach the ultimate buyer.
But don’t take out word for it – fi nd out for yourself just how effi cient GeconaTEC is!
4 New trends on the confectionery market NEWS
Development of confectionery groups Sugar candy
Internationally speaking, the confectionery market Hard caramel can be broken down into: Zefi r (Russian marshmallow), fruit jellies, pastilles, orien- • Chocolate and chocolate-containing confectionery tal sweets, Sugar-coated sweets, Toffee • Sugar candy Potential growth is harboured by: • Cakes and pastries • Moulded caramel with health-promoting properties The chocolate segment is the most profi table one and still • sugar-free products has some absolute growth potential. • jelly-products The sugar candy segment is declining internationally and • Toffee can only be stimulated by new, trendy products.
Chocolate and chocolate-containing confectionery Cakes and pastries
The main ranges are: The main ranges are: Loose chocolate sweets (fondants, chocolates and wafers) • Biscuits Chocolate tablets, Boxes of chocolates, Chocolate bars. • Wafers • Gingerbread Potential growth is anticipated in: Potential growth is to be seen in: Products made out of quality ingredients, technologically Cakes and pastries with health-promoting properties sophisticated combined products, high-quality packaging, Products with fruit or praline fi lling Combined products sophisticated secondary packaging, replacing the sale of loose confectionery out of large cardboard boxes.
5 New products
Combined chocolate products
Combined chocolate products developed by leading manufacturers have been very successful. Such products are distinguished by a mixture of high-quality components, calling for sophisticated manufacturing equipment and technology. GeconaTEC has designed production lines for the following product ideas:
Chocolate-wafer-sweets
The combination of a wide range of wafer shapes with a cream, praline or marshmallow fi lling and the addition of whole or crushed nuts, almonds or candied peel and coated or dipped once or twice in chocolate results in a fi rst-class fl avour experience. Despite the extensive range of products on the market, there is still plenty of scope for new types and combinations. However, it is important to have equipment with high productivity to ensure that these complicated products can be manufactured effectively.
Chocolate, caramel/toffee, soft brittle
Apart from traditional hard brittle, combinations of chocolate, caramel/toffee with cream as well as solid ingredients have proved exclu- sive. Such confectionery is particularly interesting when the cream fi lling is enclosed by the caramel/toffee and chocolate layers. As in a wafer, the different textures of the components make for a particularly exquisite fl avour. The development of manufacturing technolo- gies is opening up new possible combinations that can be produced effi ciently.
Chocolate, marzipan and nougat
So far almost solely available through imports, marzipan and nougat have acquired a reputation as very high-quality confectionery components. These products should in particular always be included in ranges of chocolates.
6 New products
Jelly and marshmallow products
With the exception of traditional jelly and zefi r products, entire market segments of marshmallow and shaped ‘gummi’ (rubbery-textured jelly) products are currently covered solely by imports. Figures like gummi bears, jelly babies and the like can be made out of transparent or opaque mass in almost every colour imaginable. The exact shapes produced can be geared to children’s preferences. Their texture can be adapted to range from simple jellies to something akin to chews. They can also be combined with traditional zefi r and jelly centres. The current trends are to replace gelatin with vegetable gelling agent and if possible to use natural colouring.
Cakes and pastries – pastry slices
Long pastries containing a fruit fi lling are moulded, baked and cut into bar-shaped slices.
Health-promoting products Functional products
These products are enhanced with healthy ingredients such These performance-enhancing products are especially rich in as minerals, vitamins and health-promoting substances. Mo- energy (glucose) or contain stimulants like caffeine. reover, they can be produced in low-calorie and/or low-sugar versions. Examples include: • Energy chocolate The main types are: • Chocolates with added coffee or cola • Hard caramel (with health-promoting additives, sugar-free, with vitamins and minerals) • Muesli bars
7 Technologies for new products
Chocolate moulding technology
In recent years, moulding technology has made enormous strides. Technologies such as one-shot and frozen cone combined with the use of modules in moulding systems along with robot technology enable combined chocolate products and even assortments of chocolates to be made online. Accordingly, the various benefi ts of the systems designed by GeconaTEC for mainly new products can be exploited jointly.
Assortments of chocolates of equal volume can be produced in a mould out of dark, white and milk chocolate with different fi llings in the same arrangement as they will appear in the tray. A robot is used to fi ll the tray in a single operation.
Frozen cone technology can be used not just for chocolate but also for caramel, toffee and soft brittle within a chocolate shell. The use of robots means that even the most complicated products can be taken out of the moulds and delivered to the packing process.
Moulding technology allows the inaccurate piston extruders used for the production of dome-shaped praline centres to be replaced, especially on highly productive systems. Despite the low tolerance following chocolate coating, this enables highly productive packing machines to be used.
Modern moulding systems also allow specifi c amounts of solid ingredients like nuts, almonds and candied peel to be added to the fi lling or the moulds themselves either whole or crushed.
Special marshmallow moulding heads enable exact quantities of highly foamed marshmallow to be introduced into chocolates.
Since the marshmallow is kept under pressure from extrusion until the funnel, it is impossible for the marshmallow to thicken again in the funnel.
8 Technologies for new products
Using candy bar lines for sweets
Carpet-forming machines used to make candy bars are state-of-the-art throughout the world. However, the candy bar systems designed by GeconaTEC can also be used to make smaller sweets. The layers are formed and cut so precisely that the products can be processed by high-performance packing systems. In addition to product carpets, the DP/DDP moulding press can be used for continuous extrusion. Muesli bars can also be produced on these systems.
Hard caramel moulding
Declining hard caramel sales have only been slowed down in recent years by moulded products. Clear products in bright colours with no edges are rated by customers as up-to-date. Moreover, in addition to hard caramels, modern moulding systems can also produce toffee and fondant. With suitable additives, moulded hard caramel makes an ideal health-conscious product.
Marshmallow and jelly products
The production of marshmallow and jelly products can sometimes be quite complicated since the gelling and drying time may be up to 24 hours. Although modern gelling agents can considerably shorten this time, they may impair the fl avour. Another method is to produce the compound with the fi nal moisture and only then to mould it. The advantage is that the entire moisture is bound by the gelling process and the product does not need to dry. However, this places special requirements on the dosing and boiling process. Since the viscosity of the compound containing the fi nal level of moisture is considerably higher, it needs to be introduced into its fi nal shape using special moulding techniques.
If the conditioning period exceeds 30 minutes or so, a rotating mould method is no longer effective. Instead, a special automatic conditio- ning transport room system has been developed which stores the products for up to 10 hours before further automatic processing.
9 Complete line for production of chocolate- and pralinebulk
Mixer Five Roller Mill
Rawbulk Conditioning
10 Conti-Conch Batch-Conch
Bulk Storage
11 Complete line for production and packaging of chocolate assortments
Production of Pralinefi llings Filling Kitchen
12 Moulding Implements Packaging System
Pralinebulk Storage
13 Complete line for production and packaging of chocolate bars
Preparation of Pralinefi llings Filling Kitchen
14 Moulding Line First/Secondary Packaging
15 Complete line for production of wafer confectionary
First Packaging
Secondary Packaging Wafer Oven
16 Enrober
Conditioning
17 Complete line for production of confectionary on base of brittle and nougat
Enrober Forming Device
Tempering Filling Kitchen
18 First Packaging Secondary Packaging
19 Complete system for conditioning of tea
Bag Emptying Sieve
20 System description The system includes the whole process of the manufacturing beginning from the supply of the raw material from the stock, the bag emptying, cleaning, sieving and mixing of the teasort with fl avouring. The fl avouring can be proceed with pellets or with liquids.
The ready blends are storaged in containers after the mixing and can be dispensed to the packing lines in order with the produc- tion sheme. The transportation of the tea is to be carried out by pneumatic systems. The overall performance of the system is up to 7t/h. The system can handle all teasorts beginning from Fannings up to long leaf.
Genuine Storage Mixing/Flavouring Mixture Storage
21 Complete line for packaging of tea in teabags and boxes
Perfecta
Box Erector Multi-Row Conveyor Teabag Machine
22 System description The box erector PSA is forming the box from the blank. After that the erected boxes are brought to the packaging machines “Perfecta”. These machines are producing up to 400 bags per minute and insert them in the boxes. Boxes with 20, 25, 50 or 100 bags can be fi lled up.
The conveyor system brings the fi lled boxes to the box closing device. After closing the lid, the boxes will be printed with production data, overwrapped and automatically collected in cartons with a casepacker.
The machines “Perfecta” by Teepack can produce naked teabags, teabags in paper envelope or heatseal envelope.
Overwrapper
Box Closing Device DSM
Casepacker
23 Complete line for packaging loose tea in bags and cartons
Vertical Bagger Machine/ Cartonizer Multiheadweigher
24 System description The tea is given to the vertical bagger machine with a multiheadweigher in the range from 50g up to 500g.
The vertical bagger machine is packing the tea exactly by weight into fl at bags or stand-up pouches. The fi lled bags are brought to a cartoning device, wich is is pushing the bags into small cartons. After that the fl aps are closed automatically.
The conveying systems brings the cartons to the overwrapper.
Overwrapper Casepacker
25 Complete line for packaging wafer confect in fl owpack and boxes
Feeding System Flowwrappers Packaging System for Cartons
Packaging System for Boxes
26 Complete line for packaging snacks in pouches and cartons
Vertical Bagger Machine Robot System Case Erector
Case Closer
27 Complete line for two-stage packaging of chocolate tablets in paper/carton envelope and showbox
Feeding System Wrapping Machine Casepacker
28 New types of individual packaging
PULL Pack
The Pull Pack has been developed for candy bar products by our partner BOSCH Sigpack Systems to make it easier to open fl ow-packed items. It has been implemented for fl ow-pack machines.
Just grip part of the packaging with the product (e.g. a chocolate bar) fi rmly in one hand and pull the other end with your other hand. The two halves have been prepared for simple opening by perforation and then specially sealing the packaging material.
Flow-pack or Pull Pack used for boxes
To enhance fl ow-packed items, they can be placed inside smart boxes by automatic cartoning equipment. This is suitable for both bars of chocolate and candy bars.
Protected double-twist wrapping
The product is sealed in the packaging material as in fl ow-packing. The product ends are then twisted. An incision is included in the longitudinal seam to make opening easier.
29 Automatic group packing
Customers and retailers are less and less keen on loose high-quality chocolate sweets. Loose products need to be placed in sales packa- ging as effi ciently as possible:
Showbox
The Showbox can be fi lled with bars of chocolate or candy bars by robots. The products are placed in order by the fi rst packaging ma- chine and delivered to the Showbox system. They are grouped in the quantities required and placed or pushed into the Showbox made automatically out of fl at blanks. The Showbox is then automatically closed and marked.
Small products can be poured using multi-head balances into a prefabricated Showbox made automatically out of fl at blanks. After- wards, the Showbox is automatically closed and marked.
Edge-seal fl at-ended bags
The fl at-ended bag looks similar to the Showbox. However, it’s much easier to make since the packaging material can be processed straight off the roll. To make the packaging re-sealable, the head seam can be repositioned and taped.
The product can also be packed on the same equipment in pillow bags with a eurohole.
30 GeconaPACK’s range of services
OOO GeconaPACK is a formation of GeconaTEC GmbH. OOO GeconaPACK assures to merge single equipments to a unique halfauto- matically and fullautomatically production system in the highlevel programm. The Russian company OOO GeconaPack is a team of specialists with longtime experiences in the fi eld of work with equipment by all important suppliers from Europe.
OOO GeconaPACK carries out preliminary work such as: Devising the technological part of the equipment to be supplied and preparing details about the types of energy required, Drawing up the work project for the equipment to be supplied, Technical supervision of project work, Certifi cation of the equipment ordered, Technical supervision of equipment while being built by the manufacturer.
GeconaPACK’s main activities revolve around assembly supervision: Technical, technological and organizational supervision of every stage from the assembly and start-up of the production lines or individual equipment supplied to the manufacture of the fi nished pro- duct matching the predefi ned specifi cation, Coordinating the activities of the client’s experts and contractors with the suppliers’ chief engineers, Training employees to operate equipment by themselves, Adapting new or existing engineering systems to the equipment to be supplied, Optimizing equipment functions, technological processes and production organization, Coordinating the use of new and existing equipment as well as control signals between them, including possible control system optimization, Fine-tuning production line operation until the fi nished product is manufactured smoothly to the predefi ned specifi cation within the period agreed following start- up Development and start-up of systems for logging ingredients and fi nished products.
An important range of work of GeconaPACK is the mentoring of the work of the lines or equipment after the put-into-operation: Guarantee and post-guarantee servicing as well as equipment maintenance, Optimization of production, range expansion, supply of spare parts, Troubleshooting and elimination of the source of equipment malfunctioning, Repair of equipment and individual modules, Development, production, installation and start-up of non-standard electronic control systems, mechanical modules and spare parts to replace or augment existing items.
31 CONTACT GeconaTEC® GmbH Headquarter Alt-Köpenick 39 D-12557 Berlin Germany Phone +49(0)30 65 49 40 20 Fax +49(0)30 65 49 40 21 Email [email protected]
GeconaTEC® GmbH GeconaTEC® GmbH Representation Russian Federation Representation Ukraine Ul. Bolschaja Jakimanka 31 Boul. Schewtschenko 4 119180 Moskau 01004 Kiew Russian Federation Ukraine Phone +7(495) 230 64 36 Phone +38(044) 278 06 11 Fax +7(495) 230 64 35 Fax +38(044) 279 84 78 Email [email protected] Email [email protected]
GeconaTEC® GmbH Representation Georgia and Representation Kazachstan will be established in year 2008 © gecko-design +49(0)3328-330913 © gecko-design