Latest News

Designed with the future in mind

February 2017
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FAWEMA packaging and bagging machines


by Mark Wild, Sales Manager at Fawema, Germany


With 97 years of history behind them, it would be fair to say that Fawema´s know-how and experience in the field of packaging and bagging is quite unique. But while having a long and rich heritage is of course important, ensuring a consolidated and bright future is even more important and it was with exactly this sentiment in mind that Fawema, located near Cologne in Germany, decided in recent years to dedicate their vast technical capability and resources to developing a new range of automatic packing machines, which is today radically revolutionizing the way in which flours and other powder and granulated products are packed into bags.

Servo-drive transmission
In much the same way in which the automobile industry has utilized servo-drive transmission to guarantee reliability and an easy driving experience into motor vehicles, Fawema has successfully introduced servo-drive technology into the new range of FA217 flour packing machines and the results have been truly incredible.
Thanks to servo-drive, the new Fawema packing machinery offers the user a modern machine, which is extremely reliable, totally hygienic and delivers high capacity performance of up to 110 bags per minute. An intelligent energy recovery system ensures that no power is wasted and thanks to this incorporated recovery system, the complete machine benefits from substantial overall energy savings.
The new range of machines do not require oil sumps, grease or lubrification and with increased dust aspiration ducting it all signifies a machine which is clean, perfectly hygienic and with no risk of contamination. All machine movements are precise and with no mechanical slipping or wear and tear, the results are optimal with vastly reduced costs on parts and service and improved reliability.

Changing trends: Paper and plastic packaging materials
Kraft paper in the form of ready-made, block-bottom bags has long been the preferred packaging material when it comes to retail-size flour packs from 500 grams to 5kg. Used by mills in Europe, North America, Latin America, Africa, the Middle East and Australia, kraft paper bags lend themselves well to flour packaging for a number of reasons such as competitive cost, easy to source, allow for rapid internal flour settling, easy to store and transport in brick pack form and presents well to the consumer at point of sale. Recently however, a trend in the market towards utilizing plastic packaging material has become evident and Fawema has designed, built, delivered and installed a large number of machines during the last three years for packing flour and flour-based products into retail-size plastic bags.
Plastic packaging materials come in two forms – printed reels or ready-made, block bottom bags and the characteristics, quality and thickness of the plastic vary depending on several factors such as the types of packs to be made i.e. pillow packs or stand-up brick packs, weight of the pack to be made and whether or not secondary or tertiary packaging will be utilised.

Why are some millers changing to plastic bag packaging?
The millers themselves point to three key factors:
1. Plastic material is stronger than paper hence the mills get far fewer claims and returns on damaged or broken bags.
2. The bags are closed by heat seal and then in the case of brick packs the top is folded and held down either by a resealable label or by hot melt glue. This creates a pack that is leak-proof.
3. Glossy printed plastic is an ideal marketing material, which is attractive and appealing to the consumer.
These three points are important although paper producers and paper bag suppliers will argue that there is much more to the debate than just this and that the listed points are general theories rather than specific proven case studies. Quality in both paper and plastic can vary greatly. In the case of SOS kraft paper bags, the structure quality of the bag itself depends on the type of converting machine being employed to make the bag (type of machine, manufacturer of machine, age of the machine, quality of glue used for closing the seams and whether or not the machine is set up perfectly to make consistent quality bags in large volumes).
Another major factor is the paper quality. Important paper suppliers such as Billerudkorsnas from Sweden who supply premium-quality paper to converters who then manufacture the flour bags, will rightly argue that if a good quality paper is deployed and the converter uses the correct paper thickness for the bags, the paper bags will be just as strong as plastic bags. Furthermore, a good quality print is achievable on paper bags comparable with that of plastic if the paper quality used is the right one. The paper suppliers will also highlight the environmental issue when comparing plastic v paper and the simple fact ist hat paper bags are 100 percent recyclable – something which the plastics industry are unable to claim.
The question of sealing is a topic which has many pros and cons. Naturally, if a plastic bag is hermetically sealed then product leakage should not occur and the advantages are obvious.
The downside to this is that before a plastic bag can be closed, all of the internal air must first be evacuated otherwise the bag will resemble a balloon, be susceptible to bursting, be unstable and will result in a physically unattractive package. Evacuating air takes time and therefore a longer than standard product settling track is required on the packing machine. Paper bags have the feature of being porous to air so any air inside a paper bag will eventually be evacuated even after the bag is closed.

Versatility and simplicity are key
In today´s ultra-competitive business world, capital equipment investments are essential to stay ahead of the field. Market demands constantly rise and packaging trends driven by consumers who are increasingly more sophisticated in their buying habits are always changing, therefore the milling industry must address the challenges of packaging as one of the primary elements of their business.
‚Retail is detail’ and when it comes to retail food, the consumer is even more conscious of the need for quality in both the food product itself as well as the packaging. The need to make the right investment in a packing machine or system has never been more important and versatility and simplicity are key factors to be considered in selecting the right equipment.
A machine must be as versatile as possible in order to meet the ever-changing trends and requirements, but it should also be user-friendly and simple to operate. At Fawema, our belief is that we have created a range of flour packing machines that meet these criteria. The new Fawema equipment designed and built for the 21st century is versatile, reliable, simple to use and offers the very best solutions to high-capacity throughputs, weight precision, energy savings and food safety.

Innovation never stops
Innovation is never-ending and research into new technology and future improvements in flour packaging is always a top priority at Fawema. Please watch this space because even more exciting new things are coming soon!


February 2017 - Milling and Grain


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News January 2017

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The New year is here and 2017 promises to be an exciting and busy year for everyone involved at FAWEMA. Record numbers of orders, thanks to the key advancements made on FAWEMAs leading product lines, mean that the company is in a great position to grow and look at developing new ideas that our customer base wants incorporated in the next generation of packaging lines.
2017 is the year of the Interpack show in Dusseldorf, Germany, the largest meeting on packaging industries calendar. FAWEMA will be Exhibiting in Hall 6, Stand 6C31, and will be bringing new concepts, ideas and showing you what you can expect from us in the future. We will be giving demonstrations throughout the days and will have our brightest engineering talent on hand to take you through the machine.
Being a global company, in which last year over 70 percent of our business was done outside of Europe, we will also be attending shows in every continent and hope very much that you may be able to join us. We will be attending:
Upakovka in Moscow, Russia from the 24th-27th January
TUSAF in Antalya, Turkey from 30th - March 2nd April
IAOM north America in New Orleans, USA from 10th- 14th April
Interpack in Dusseldorf, Germany from 4th-10th May
IAOM in Dubai, UAE from 22nd–25th October 
ALIM in Latin America
These are just some of the shows we will be attending in 2017, giving you the opportunity to catch up with long known FAWEMA personnel and meet those newer members of the team. We hope it will give you a the opportunity for us to inform you about the latest developments and help you to find a solution for your packaging needs in the future.

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End of year review

December 2016
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Winter is here and the first snow has already fallen, but here in Engelskirchen work doesn’t stop and our busy little Elves are working hard to complete the last machines in 2016. It’s been a great year for FAWEMA with record numbers of machines rolling out the doors and this is set to continue well into 2017. At the beginning of the year new developments to already good machines were made, bringing both new opportunities to the market and continuing FAWEMAs strive for innovation and solutions. FAWEMA has entered new markets around the world for the first time in 2016 and has seen sales of its flagship, high capacity machine increase for another consecutive year. This along with an ever-increasing appreciation for FAWEMAs dry pet food packing lines have meant that the company is in a great position to push on with the successes made this year well into the future. With Pet food demands around the world on the increase, we hope for continued success to come from our specifically designed Pet food lines. Further R&D work in the middle of 2016 has meant that FAWEMA can now offer the packing of grouts and tile adhesives at retail sizes at competitive speeds. The machine also offers an air tight solution and a fully compacted and settled plastic bag.

 

The second half of the year was again very positive, with a well-balanced order book coming from a large range of industries. We again saw continued strong growth coming out of the African market and leading milling companies choosing FAWEMA for their packaging lines. We also delivered machines into the Chinese market and are continuing to expand the business in the Far East. In November FAWEMA launched its latest innovation the FA456 large Pet food packaging machine. This now gives the company the ability along with the FA438 to pack weights up to 25Kg.

 

In 2016 FAWEMA attended shows all around the world and had the opportunity to meet new faces in the industry and catch up with old friends. FAWEMA was honoured to actively support and participate at the following events during the course of 2016.

 

TUSAF, Turkey - IAOM-SEA, Thailand - IAOM-MEA, Ethiopia - GULF Food Manufacturing, Dubai - Pack Expo, Chicago, USA - IAOM, Columbus, USA - ALIM, Puerto Rico - FachPack, Germany - Upakova, Moscow, Russia

 

We will continue to have a global presence in 2017 and we hope that you can join us at a show near you. Please pay close attention to the website for new announcements and look out for where we will be exhibiting in the coming year. Alternately come and see us at Interpack in Düsseldorf on the 4th-10th of May, where we will be presenting new concepts for the future.  

 

From all the staff at FAWEMA, a very big thank you to all our valued clients and wishing you all a very happy and successful 2017!

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It does not get any better!

The IHK (German Chamber of Commerce) honours the best apprentices
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With an A on their examination certificate, the best trainees from the region honoured by the IHK Nord Westfalen have laid an excellent foundation for their professional careers. The regional “honouring of the best” underlines the outstanding achievements of the young trainees as well as their training businesses ranging from manufacturing industry, to trade and service. We would therefore like to congratulate our mechatronics engineer Johannes Spicher (in the picture on the right, next to the General Manager Adrian Mitas), who has been distinguished for his excellent test results. FAWEMA offers a wide range of high-quality training opportunities for pupils, school-leavers and students in a future-oriented and interesting industry. An education in a modern workplace, with a good working environment and development possibilities are important matters for us.

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Besser geht es nicht!

IHK ehrt die besten Azubis

Mit der eins vor dem Komma auf dem Prüfungszeugnis haben sich die von der IHK Nord Westfalen geehrten besten Auszubildenden aus der Region eine hervorragende Basis für ihre berufliche Karriere gelegt. Die regionalen Bestenehrungen unterstreichen die herausragenden Leistungen der jungen Nachwuchskräfte sowie ihrer Ausbildungsbetriebe aus Industrie, Handel und Dienstleistung. Besonders gratulieren möchten wir deshalb unserem Mechatroniker Johannes Spicher (im Bild rechts, neben Geschäftsführer Adrian Mitas) der für sein hervorragenes Prüfungsergebnis ausgezeichnet wurde. FAWEMA bietet für Schüler, Schulabgänger und Studenten ein breites Spektrum an qualitativ hochwertigen Ausbildungsmöglichkeiten in einer zukunftsorientierten und interessanten Branche. Eine Ausbildung an modernen Arbeitsplätzen, mit gutem Betriebsklima und Entwicklungsmöglichkeiten sind uns dabei ein Anliegen.

FAWEMA GmbH , Engelskirchen

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FAWEMA at Cologne Marathon

October 2016
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On the 2nd of October the 20th annual Cologne marathon was held and 2 teams from FAWEMA decided to participate in the team marathon event. Each member of the 4-man team ran a leg around the city, with the final runner finishing in front of the Cologne Cathedral. It was a fantastic morning for the 20,000 plus runners who set off from the eastern side of the river and the weather was good, providing perfect temperatures for long distance running. The support was outstanding by the friends, family and Cologne locals who came out in their droves to support the professional and fun runners, creating a carnival like atmosphere around the 42km course. Both teams completed the run in under 4 hours and made sure after, that they were well rehydrated with a few of the local Kölsch beer.
It was a fantastic day out and something, which every single member of the teams would like to do again next year. We would like to thank Thomas Gantenbrinker, Ben Heß, Guido Höndgesberg, Oliver Kampmann, Frank Balensiefer, Luke Thomas, Arash Mahmoudi, Tim Lüdenbach for the great efforts they put in and showing a great team ethic. Well done team FAWEMA!!

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African milling group chooses
Fawema for flagship project
in South Africa

October 2016
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African milling group chooses Fawema for
flagship project in South Africa

The Bakhresa Group of Companies is already firmly established in several East African nations since the
company first moved into the milling industry from their base in Tanzania in the early 1980’s.
The group’s chairman and founding father Mr. Said Salim Awadh Bakhresa, from humble beginnings, has developed a highly successful business empire based largely on his own personal ethics of hard work and integrity coupled with exceptional vision and superb management skills. The group’s ambition for further expansion in Africa saw them recently establish Bakhresa South Africa (Pty) Ltd. And purchase a site in Durban, Kwazulu Natal on the Indian Ocean coast, an ideal logistical and geographical location.
The chosen site was actually an existing mill that had  been non-operational for several years – the Union Flour Mills was originally built in 1906 but required total redevelopment, expansion and of course - re-fitting with new, 21st century machinery and equipment.
The new mill would have a daily capacity of 750 metric tonnes. For the flour packing machinery, Bakhresa turned to Fawema, safe in the knowledge that Fawema had already supplied equipment for all their other mills in East  Africa over the years.

Fawema’s vast wealth of knowledge and experience.
As this was Bakhresa’s first venture into South Africa,  they were also able to tap into Fawema’s vast wealth of knowledge and experience of the market, which in terms of packaging, is very different than that of East Africa.
Mark Wild, Fawema sales manager for Africa explains, ‘in East Africa, the standard retail flour pack sizes are 1 kg and 2 kg. Those packs are then baled into 24 kg baler sacks for storage and distribution. In South Africa the standard pack sizes are 1 kg, 2.5 kg, 5 kg, 10 kg and 12.5 kg; with the 1, 2.5 and 5 kg bags being collated and shrink wrapped in plastic bundles for storage and distribution. Therefore, right from the start of the project, we had to calculate correctly what the throughput volume targets should be on each bag size and plan-in the most suitable packing machinery for the task, bearing in mind also that floor space had to be utilized in the best way possible’.
A commercial and technical proposal was tabled by  the Seller and accepted by Bakhresa and immediately
afterwards, Fawema’s design department in Germany set to work with the necessary floor plan layout for a total of four fully-automatic packing lines and commenced building the new flour packing lines. Once manufacturing work was completed, the FAT (factory acceptance test) was conducted at Fawema’s large workshop and HQ near Cologne in Germany. The mill manager, himself from South Africa, personally attended the pre-delivery inspection and testing and this offered the perfect opportunity to acquaint himself with the
machinery and to gain direct hands-on experience of every aspect of the equipment. It was also a chance for him to personally meet with key Fawema personnel involved on  the project and to engage in question and answer sessions around the various machines on the shop floor at Fawema to ensure that everything was totally clear, ticked and understood.
 When the equipment finally arrived at the mill in Durban, Fawema’s local service team based near Johannesburg took care of installing each of the four packing lines and ensuring that the flour feed system to each machine was  correctly fixed in place. Once the mill  was up and running and flour was readily available, a Fawema  commissioning engineer arrived from Germany to carry out  final start-up work on the machinery which went very smoothly thanks to the FAT  testing already carried out in Germany.

‘A remarkable achievement’
Sudhakar Akella is the mill manager at Bakhresa South Africa; he’s a man with plenty of milling experience, the last 15 years of which have been spent within the Bakhresa Group operating at various locations in Africa, but this new project has been the most exciting and satisfying challenge so far. Sudhakar explained, ‘Our new mill project in Durban has been a very exciting time. Bringing back to life one of South Africa’s historic mills has been a remarkable achievement.
Due to the history of the building, large parts of the structure are protected under the national heritage law and consequently a lot of very clever and innovative mill was re-designed to be a modern, 21st century fullyfunctional facility. This we have achieved and the result is magnificent.
We had no doubt or hesitation in contracting Fawema to supply the flour packing machinery as they have always supported us on all of our previous projects throughout Africa and I’m delighted to say that also this flagship project in Durban has been successfully concluded in a disciplined and thoroughly professional manner and our flour packing section is functioning exceptionally, just as we envisaged’. Fawema wishes to thank Mr. Sudhakar Akella and the Bakhresa Group for their contribution and permission to publish this article.

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How you should pack your tea
for best results?

September 2016
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You may have noticed the simple packaging we use when packaging tea. These reusable, reseal able plastic and paper bags block all light. Used properly, they will protect against odours, oxidation, and moisture. Cheaper tin containers or decorative boxes, usually do not provide an airtight seal, because the seams are not welded together. Usually they will not protect teas for more than one month.
Tea must be stored correctly to maintain freshness. Tea, like spices, is best when fresh. Stale tea loses much of the magic. Tea is particularly susceptible to oxygen, smoke, light, and moisture. Smoke and steam all permeate and if tea is not in an airtight environment, it will absorb all those flavours and moisture. Tea is able to hold onto other flavours very well, which is why there are so many flavoured teas out there.
The benefits of packing tea in FAWEMA machines

FAWEMA packaging machines have been specifically tailored to the industry’s high demands in terms of quality and gentle product handling They offer superior performance and effective product densification.

The transport system is extremely gentle on the packaging and suited even for high gloss packaging materials. Depending on the requirements, the packaging material can be paper/aluminum laminate or plastic. The bags may be pre-made or from film-reel during the inline process.

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Reliability and Longevity

August 2016
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As the Old Proverb goes 'If it ain’t broke, don’t fix it.' Leave something alone; avoid attempting to correct, fix, or improve what is already sufficient. Well although we here at FAWEMA are continually pushing the boundaries of the latest packaging technologies, it is always nice to hear that a machine we produced over 4 decades ago is still in daily operation.
Produced in 1973 for a mill in Ireland, this FA 320 is still packing flour like it was some 40 years ago. Now this old timer is an integral part to the packing line at a Mill in Northern Ireland, Belfast, reliably turning out 30 bags per minute in the range of 1 - 5 kg. It is testament to the care and service that this machine has had, that it still runs so well today. This high quality German Built machine oozes what the FAWEMA name stands for, a durable work horse, hand crafted by experienced Engineers.
FAWEMA today, proudly turns out, built to last machines, from the same factory in Cologne Germany where this FA 320 rolled out of the door so long ago. We hold dear the ingrained values passed on year, after year, from teacher to apprentice, to keep delivering trusted, high capacity packing machines for the 21st century. With our machines now needing minimal maintenance due to integrated servo-drive technology, you can rest easy, that doing business with us is the best decision you will ever make.

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An anniversary and a Milestone

July 2016
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An anniversary and a Milestone

For us here at FAWEMA, this year marks a milestone for one of our most requested and innovative machines to date. The FA 217, servo-driven, high speed packing line has its 5th birthday this year, and what a first 5 years it has had. With over 60 machines delivered successfully to date and 11 more on order, this highly flexible, retail packing line is proving a hit in the market.

Installed in 25 countries, this dream machine incorporates the latest in design, and combines it with the traditionally proven packaging process, that FAWEMA has developed here in Germany, for over 90 years. The Application options the FA217 offers have grown since its launch in 2011, leading to a full range of machine lines, able to cater to all the packaging needs, within its 0.5kg – 5kg weight range. The multi-functional FA 217 can integrate bag forming, filling and sealing technology, a wide range of pre-made bag delivery magazines and its various bag closuring heads. The success of this market leading machine is a testament to the experienced FAWEMA Engineers, who have produced such a durable and flexible machine.

A high level of Customer satisfaction and a commitment to being a long term, trusted partner have gained many accolades in the milling industry and this is evident of its success. Mr. Kozlu of Misun Mills in Northern Turkey explains: 'since we started production with the FAWEMA equipment, packages have become more regular, the production rate is far greater, the machine is more reliable and downtime caused by stoppages or faults has been eliminated. We can work non-stop and this has benefitted our shift efficiency accordingly.'

If you would like to find out more the FA 217 and what it could do for your business, then contact us now and get a free Quote today.

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New Fawema Development for packing grouts and tile adhesives

June 2016
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New Fawema Development for packing grouts and tile adhesives

For a leading producer based in Asia, we are delivering equipment to pack grouts and tile adhesives in ready-made bags of both plastic and paper in a size range of between 1 kg and 5 kg. With speeds of up to 35 bags per minute, the client

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New Fawema Development for packing grouts and tile adhesives

For a leading producer based in Asia,  we are delivering equipment to pack grouts and tile adhesives in ready-made bags of both plastic and paper in a size range of between 1 kg and 5 kg. With speeds of up to 35 bags per minute, the client selected Fawema as the supplier due to our ability to tailor-make equipment based on very specific requirements and which comply to highly-stringent technical parameters and regulations. Indeed the equipment is designed and built with 4 key points in mind: Flexibility in terms of packaging materials to be used and closing methods incorporated, machine strength and durability when working with aggressive and difficult products, good, constant throughputs required on a daily 3 shift cycle and finally simplicity of use for the machine operator.

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MACHINE OPEN DAY at FAWEMA

May 25-30, 2016
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25TH/30TH MAY MACHINE OPEN DAY

 

FA438 viewing day
We have the pleasure of inviting YOU to come and view FAWEMAs industry leading Pet Food Packaging Machine. FAWEMA will be holding open Days for the Pet Food specific FA438 Machine on 25th and 30th of May.
The FA438 is a versatile & fast carousel-type packer with servo drives, capable of packing 60 bags/minute from 0,5 – 10Kg.

 

Tel.: +49 22 63 716-0
l.thomas@fawema.com

 

Download Open Day Poster (PDF):

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The challenges of an exciting new packing project

FAWEMA CASE STUDY
Milling and Grain Magazine
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The challenges of an exciting new packing project

On the outskirts of the town of Amasya, stands the impressive and modern flourmill of KOZLU Gida, also known as Misun. This leading Turkish mill has chosen FAWEMA for exciting new packing project

Amasya, located in northern Turkey near to the Black Sea coast, is a place of outstanding natural beauty. Established in the 4th century BC, the town has been the home of a number of civilizations and cultures and has witnessed many transitions of power. Today the town is a thriving hub for fruit agriculture, especially apples, and also for tourism both domestic and international.

On the outskirts of the town of Amasya, stands the impressive and modern flourmill of KOZLU Gida, also known as Misun. The origins of Kozlu date back to 1940’s when the company was originally established with a small wheat mill in Amasya having a daily capacity of just 16 tonnes. Over the years, the daily milling capacity gradually increased but when the decision was taken to build a new, state-of-the-art mill for 900 tonnes per day, this put Kozlu on the map as one of the top millers in Turkey. Later this year, with further expansion work, the capacity will reach 1500 tonnes per day.

Today, Kozlu is still a family-run business with 3 generations of the family involved in the management of the mill and the philosophy has always been the same: seek the very best in each and every aspect of the business. With this progressive philosophy in mind, the Kozlu family decided unanimously to award FAWEMA the contract to supply a new automatic flour packing line to pack retail-size flour of 1 kg 2 kg and 5 kg. in ready-made paper bags.

Mr. Emir Kozlu explains the criteria behind the decision: “we wanted the best quality flour packing machine available on the market because we wanted to achieve the best possible results”.

Fawema proposed the FA217 machine and the modern and advanced technology included in the packing line perfectly matched the client’s aspirations and objectives. Thanks to modern servo-drive, the machine is extremely accurate and the wear & tear drastically reduced compared to mechanical cam-drive machinery.

Furthermore, the machine needs no oil bath or lubrication, which means an overall cleaner working cycle and no risk of contamination with the flour. There are very few wearing parts, no rubber suction cups and access to all parts of the machine is immediate and easy.

The deal was agreed and once the order was placed, Fawema set to work at their base near Cologne in Germany. Firstly a layout drawing was produced indicating the footprint of the new line inside Kozlu’s mill and once the customer gave approval, Fawema’s engineers and technical personnel began the design and manufacturing process. Kozlu was always kept well informed on progress and soon the new packing line was ready at Fawema’s factory for inspection and FAT (factory acceptance test).

For this important stage of the project, Fawema invited Kozlu to send key technical members of staff from the mill in Turkey to witness the machine testing which was done recreating the same conditions as those at the mill, by using wheat flour and the original paper bags utilized by the customer. The FAT also serves the purpose of making a personal introduction between the customer himself and the specific Fawema engineer who would then later install and commission the line at the mill. This seemingly casual introduction is actually extremely valuable – for both sides – as it allows the two parties to engage in question and answer sessions while the machinery is still on the supplier’s workshop floor.

Once the machine inspection was completed and the testing was successfully done to the Buyer’s satisfaction, an in-house training program took place for the Kozlu members of staff. Great importance is placed on this primary training program and justifiably so because it allows the customer’s technical personnel to familiarize themselves with the new equipment before the machinery reaches the mill and gives the opportunity for them to operate the line under the watchful supervision of Fawema engineers. Any minor snags or details can be ironed out at this time ensuring that once the new machinery arrives at the final place of installation, it is tried, tested, certified and approved by both sides, which guarantees a speedy and trouble-free installation and startup.

Installation work at the Kozlu plant started with the challenge of hoisting the machinery from ground level onto a high-level floor of the mill and brought inside the building via an open access point. This was successfully done and then it was just a question of laying out the line as was indicated on the Fawema installation drawing and the final commission work commenced. Thanks to the factory acceptance test already carried out at Fawema’s workshop in Germany, the machine commissioning was swift and efficient with the Fawema engineer and the Kozlu technical staff working together as a friendly, well-organised and well-disciplined team.

Once commissioning was successfully completed, a final training session was undertaken to ensure that all the Turkish staff were totally happy and confident with every aspect of the machine operation, before official handover of the line from Fawema to Kozlu was celebrated with a round of excellent, freshly-brewed Turkish tea!

Mr. Emir Kozlu is delighted with the final result: “we needed a machine that would not give us any problems, which would deliver perfect packages and which would work for many years to come. We are very satisfied with Fawema, we have never faced any difficulties and we understand now that we made absolutely the right decision in choosing Fawema as our supplier”.

Kozlu had worked previously with packing equipment from another source, which functioned on a rotary cycle with mechanical cam-drive but since the installation of the new Fawema linear-design machine with modern servo-drive technology, huge improvements have been evident. Mr. Kozlu explained: “since we started production with the Fawema equipment, packages have become more regular, the production rate is far greater, the machine is more reliable and downtime caused by stoppages or faults has been eliminated. We can work non-stop and this has benefitted our shift efficiency accordingly. The final shrinkwrapped bags of flour are more compact and tightly-bundled compared to before and this means easier and safer storage on pallets in the warehouse”.

Fawema wishes to thank Kozlu Gida for placing their trust in Fawema and to Mr. Emir Kozlu for allowing us to use his words and comments for this article.

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Packaging machines for bespoke products

FAWEMA CASE STUDY
Milling and Grain Magazine
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Packaging machines for bespoke products


When demand for bread and cake mixes called for new facility, it also posed the challenge of how to package these bespoke products

G.R Wright and Sons became a FAWEMA customer when in 1973, they took delivery of their first automatic bagging machine for flour.
What was to become a long and fruitful relationship initially between Ken Wright, (the current Managing Director David Wright’s father) and FAWEMA’s family owners, begun when Petzold & Company, FAWEMA’s UK representatives brought the two enterprises together.
This relationship continues today after more than 43 years. Since 1867 Wright’s have established themselves across the UK as millers of the finest quality flours, and throughout this time they have built a strong relationship with FAWEMA with more and more packaging lines added in subsequent years.
It was after Wrights had developed what was to become their highly successful range of bread (and later cake) mixes in the 1990s, that David Wright and Production Director Alan Cave naturally came to FAWEMA again in 2014 for specialist high speed packaging equipment.
Sales of this revolutionary product range outgrew the current location in the mill, so they decided to invest in a multi-million pound new build at Delta Park, Enfield conveniently located just minutes from the mill.
This new facility features a state of the art test bakery, training workshops with a product development team that can be made available to customers, plus of course a packaging department with two new high speed FAWEMA bagging lines that fulfill the latest demands of the UK supermarkets.
Until Delta Park was built, these pioneering 500g bags, sized specifically for domestic bread making machines as well as home bakers, had been packed on existing FAWEMA dedicated retail wheat flour packers at the mill.
FAWEMA’s decades of experience in designing, building and installing bag packaging lines for difficult products like flour-based mixes with high fat and oil content placed them in the forefront when Wrights were deciding who was going to be awarded this prestigious contract - especially when it came to ensuring extremely consistent weight accuracy, essential for perfect results in the kitchen.
The finely balanced recipes include ingredients as diverse as carrot, cheese, onion, garlic, chocolate, ginger, and linseed. To guarantee this high quality, each individual mix must not only have the correct proportion of ingredients consistently and homogeneously mixed, but every bag must have an accurately
weighed dose, in this case 500g, which is where FAWEMA’s expertise comes to the fore.
If the weight varies too much then the final result can be compromised at home whether hand or machine baked. It is for this reason that FAWEMA specified their industry-leading bulk fill and weight controlled top-up system with continuous monitoring and data recording where you can interrogate every individual weight and specify very close limits and any pack outside these limits will be rejected automatically.
The feed system designed for optimum clean down and FAWEMA’s own auger fillers with quick release hoppers, singled out this equipment for rapid product change for an application that includes currently 14 different varieties for bread and 5 for cake.
After filling, the packs are retained in pockets throughout the line that includes intensive settling of the mixes, and secure bag closing and gluing thus optimising the final pack appearance for maximum impact at the point of sale.
Automatic FAWEMA collating and shrinkwrapping equipment completes each packaging line.
Today, FAWEMA’s team of specialists are responsible for delivering up to 50 complete packaging lines a year. The programme encompasses German designed and engineered bag making, filling, closing, collating and wrapping products as diverse as flour, mixes, sugar, oatmeal, pulses, dry and semi-moist pet food, charcoal, building powders, confectionery, tea, potatoes, in fact the list is endless.
Pack weights from a few grams up to 25kg and more can be processed at modest rates for those who require an entry-level unit
right up to world-leading production speeds of in excess of 100 bags per minute.
Machines for pre-made bags and sacks as well as operating from roll stock are FAWEMA’s core business. Secondary packs of collated bundles wrapped in shrink wrap film or Kraft paper are also designed and built in the factory in Engelskirchen, close to Cologne, Germany.

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New Fawema Development for packing flours and cake mixes

March 2016
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New Fawema Development for packing flours and cake mixes:

For a leading international brand, we have delivered new equipment to pack flours and cake mixes in ready-made retail-size plastic bags. The presentation of these bags is superb and now offers the user an attractive alternative to packing in p

... more

New Fawema Development for packing flours and cake mixes:

For a leading international brand, we have delivered new equipment to pack flours and cake mixes in ready-made retail-size plastic bags. The presentation of these bags is superb and now offers the user an attractive alternative to packing in paper bags.  The automatic packing machine is based on our modern and innovative FA217 servo-drive line with benefits of reduced maintenance requirements, improved product settling and improved overall hygiene thanks to the elimination of an oil bath.  Throughputs are high and the final closed 1 kg bags are collated and passed through a shrink tunnel to achieve a shrink-wrapped multi-pack which is easy to palletize either automatically or manually.

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New Fawema Development
for packing pet foods

February 2016
news_2_2016.jpg

New Fawema Development for packing pet foods:

We are currently designing state-of-the-art fully-automatic machinery for a leading international producer of dry extruded pet food. The machinery will operate with ready-made bags in both plastic and paper and will fill at speeds up to 60 bags per minu

... more

New Fawema Development for packing pet foods:

We are currently designing state-of-the-art fully-automatic machinery for a leading international producer of dry extruded pet food. The machinery will operate with ready-made bags in both plastic and paper and will fill at speeds up to 60 bags per minute on sizes of 1 kg to 4 kg. The machinery will be extremely user-friendly and will incorporate closures using heat-seal for the plastic bags and glue for the paper bags. Front zipper bags will also be utilized on the machinery which will prove the equipment to be well and truly flexible while maintaining high throughputs.

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