Packaging snacks is a big challenge for machine flexibility because of the many different product formats and quickly-changing batches. The Walgau-Bäckerei Stuchly bakery chose the FlexFlow digit model of the Saropacker flow pack machine. Bakery owner Martin Stuchly explains in an interview how they came to that decision.

The Walgau-Bäckerei Stuchly GmbH bakery in Bludesch-Gais/­Austria has experienced strong growth in past years. The company employs 24 workers in four stores. High quality, handmade baked goods like bread rolls and snacks, which are then sold in vending machines, are a booming business. The company sought a faster packaging machine for this purpose, as large quantities of baked goods have to be packaged in a short time in the early morning hours.

sweets processing: Mr Stuchly, why did you choose Saropack?
Martin Stuchly: The great contacts we’d had previously were the main reason. Saropack was very engaged and supported us well in finding a solution for our high demands. Furthermore, the spatial proximity to technical service was very important.

sp: Which project steps were important during your decision?
Stuchly: Saropack organized a preview from the start. There, we were able to test our various products on the packaging equipment in real life. This gave us the certainty we needed to decide for the purchase. Saropack also gave us tremendous support in determining suit-able films, optimal film width, as well as the required film perforations. Because of the many different product formats and small batches, we wanted to change rolls of film as little as possible, of course.

sp: Which objectives did you set for the new packaging solution?
Stuchly: Previously, we had operated semi-automated machines. Due to new contracts, we had to package much more products in a shorter amount of time. We had to be more efficient. In addition, we needed the option to print on the film. Selling product via vending machines involves special labelling requirements for the packaging. It was also important that products be presented in an attractive manner conducive to sales.

sp: Which standards did you set for the film packaging and for your partners in general?
Stuchly: We maintain a friendly, open relationship with our suppliers. A high level of trust in our point of contact was very important to us. Of course, the packaging also had to look good, the equipment had to meet our needs and make for an economical investment.

sp: How were you able to meet your objectives and needs?
Stuchly: Saropack recommended the purchase of a Saropack FlexFlow digit 600 flow pack machine with automatic film printing. Now, we can consistently package 4,000 products in just three hours. The machine capacity could be higher, but it is limited by the quickly changing formats and employee throughput. We still have reserve capacity. We define the print layout ourselves with a special software and label the packaging film with all required information.

sp: Which benefits resulted from the new solution?
Stuchly: Previously, we had worked approximately six hours each morning for packaging. With the new machine, we’ve reduced that working time by half. As a result, the employees can tend to other functions during the busy morning hours.