Food

Lightline Case Packer for Delica

Automated packaging of Delica product cartons using top-loading technology.

Coffee Capsules, Compactly Packed

  • Tray-and-hood packaging of coffee capsules in just 2.5 × 3.5 metres of floor space
  • Up to 120 cartons per minute — 15 shipping cases per minute
  • Double facing: two rows of four individual cartons, each holding 20 capsules, per shipping case
  • Fast format changeovers in just a few minutes, thanks to redesigned, lighter F2 robot tooling
  • Up to 20 minutes of autonomous operation for maximum operator relief

Challenge

High Performance in Minimal Space

Coffee and capsules are a well-established pairing — and at Swiss company Delica AG, part of the Migros Group, production runs at full speed across five sites. At the central coffee facility in Birsfelden near Basel, the task was clear: pack significantly more coffee capsules into shipping cases, and do it within a footprint of just 2.5 by 3.5 metres. What was needed was a compact case packer for a tray-and-hood application — one capable of erecting, filling and closing two-piece blanks consisting of a tray and a separate lid. The configuration also called for a so-called double facing: two rows of four individual cartons, each containing 20 capsules, sit side by side in a tray, with the front face of the first two cartons visible from the outside — creating an appealing presentation at the point of sale. "We wanted to be able to pack more than a hundred cartons per minute in a confined space, and to do it as simply as possible," says Angelo Teta, Project Manager and Deputy Head of Engineering Birsfelden at Delica.

Solution

Proven Technology, Rethought

For this demanding brief, only one solution fit the bill: the third Lightline machine from Schubert for the Birsfelden site. Schubert's pre-configured Lightline machines stand out for their rapid commissioning, straightforward operation and plug-and-play tool changes — exactly what Delica was looking for. At the heart of the system are redesigned F2 robots that handle the core tasks of erecting, filling and closing. Their tooling has been deliberately made lighter and simpler: operators can switch formats in just a few minutes with no additional adjustments required, as the machine automatically cross-checks its program against the format parts currently in use. The new aluminium magazine plates — featuring finger recesses and rubber rollers — reflect the same ergonomic thinking. The result: up to 120 cartons per minute in a minimal footprint, with plenty of room to grow. And with up to 20 minutes of autonomous operation, operators are free to attend to other tasks while the machine reliably does its job.

Christiane Buchstab

We know Delica's packaging world very well by now. If needed, the machine can be equipped with new format parts.

Christiane Buchstab

Sales Account Manager, Gerhard Schubert GmbH

Technical details

  • Machine type: Lightline Case Packer
  • Application: Tray-and-hood (two-piece blank: tray + removable lid)
  • Footprint: 2.5 × 3.5 metres
  • Output: up to 120 cartons per minute / 15 shipping cases per minute
  • Pack pattern: 2 rows × 4 individual cartons of 20 capsules per shipping case
  • Robot type: F2 robots (erecting, filling, closing)
  • Format changeover: within minutes, no additional adjustments required, automatic program verification
  • Magazine plates: aluminium, with finger recesses and rubber rollers
Robots packaging: On the left, an F2 picks up a cardboard blank; in the background, an F2 places eight boxes into an upright shipping crate.

Flexibility on Multiple Levels

The Lightline machine in Birsfelden is built with growth in mind. The current format — a shipping case with a tray and an externally glued, removable lid — can be extended at any time to accommodate additional formats or even entirely different products. Instead of coffee capsules, Delica can use the machine to secondary-pack other products whenever the need arises. Flexibility, then, operates on several levels at once: across formats, product types and staffing. For a company as broadly positioned as Delica — producing at five sites in Switzerland alone and handling everything from coffee and biscuits to chocolate, chewing gum and parboiled rice — this kind of versatility is not a bonus. It is a baseline requirement. With the third Lightline machine now running in Birsfelden, Delica continues its long-standing partnership with Schubert in a consistent and purposeful way. And one thing is already clear: this case packer will not be the last Schubert machine on site.

more impressions