Automated Packaging of Knight-style Sports Variety

In an innovative move towards sustainability, Ritter Sport, the renowned chocolate brand from Baden-Württemberg, has unveiled a new packaging solution for its popular 100-gram bars. This groundbreaking development, which aims to reduce storage space and cardboard usage by 30 percent, was made possible through a collaboration with Schubert, a leading packaging technology company.

The heart of the new system is a compact machine, designed with flexibility in mind. It can be optionally connected to Ritter Sport's existing packaging machine, allowing for alternative carton packaging via an additional height-adjustable swivel belt. The machine consists of a transfer unit, three F2 robots, and a downstream turning unit, all housed within a single frame.

The F2 filling robot is responsible for taking the products from the grouping chain and placing them upside down in the lid of the box. Another F2 robot seals the attached bottom part of the box, while the third robot seals the box with the attached bottom part. The ready-to-sell Ritter Sport boxes are then rotated 180 degrees in the turning unit.

One of the key advantages of the new system is that it eliminates the need for time-consuming format changes during operation. Prior to this solution, sorting and final packaging had to be done manually due to the varying dimensions of the different types of Ritter Sport's 100-gram bars, which can differ by up to three millimeters in thickness.

Ritter Sport's commitment to sustainability is evident in this new packaging project, as they are currently testing a new type of special paper packaging. The boxes used for the 100-gram chocolate bars are now single-piece blanks, erected from flat storage.

Alfred Theodor Ritter, the founder and former Managing Director of Ritter Sport, received the German Founders' Award 2019 in the Lifetime Achievement category. Today, Ritter Sport offers more than 22 delicious varieties of chocolate treats, and this latest innovation in packaging is a testament to their continuous efforts to improve and innovate.

While the name of the project manager who developed the compact machine for Ritter Sport is not currently available, it is clear that this collaboration between Ritter Sport and Schubert has resulted in a significant step forward in sustainable packaging solutions. The packaging process of the 100-gram bars was recently reviewed from a sustainability perspective, and this new system is a clear demonstration of Ritter Sport's commitment to reducing waste and promoting eco-friendly practices.