Dubai Bakery Opts for ATCOPACK Flow Wrapper for Reliable Packing

A Dubai-based bakery was facing increasing pressure to improve packing speed and consistency as production demand grew. While the production line was stable, the packing section was unable to match the output, creating delays in daily operations. In many UAE bakery operations, the packing section often becomes a bottleneck as production demand increases.

Existing Process
The packing of biscuits and snack cakes was handled manually. This limited the output to around 25–30 packs per minute and required multiple workers to maintain production targets. Variations in sealing quality and increased product handling also led to wastage and hygiene concerns.

Challenge
The client required a solution that could improve packing speed, reduce manual dependency, and maintain consistent sealing quality without affecting delicate products such as cream biscuits and soft snack cakes.

Solution Implemented
ATCOPACK supplied three Horizontal Flow Wrapper machines (Model: AFW-250B(S)), widely used for biscuit packaging in Dubai and UAE production facilities. The machines were equipped with rotary sealing and independent servo drive systems, ensuring synchronized control of product infeed, film movement, and sealing operations.

A customized infeed system was provided to ensure smooth handling of products, reducing the risk of damage. The machines were integrated with a feeding conveyor and an online date coding unit, allowing continuous operation.

Installation and Setup
Installation was completed within two days. Due to space constraints and product size variations, minor adjustments were made during commissioning to align the system with actual production conditions. Operator training was provided to ensure smooth daily operations and basic troubleshooting.

Results Achieved
After implementation, packing speed increased to around 90 packs per minute per machine. Manpower was reduced from six workers to two operators per line.

Sealing consistency improved, wastage was reduced, and hygiene standards were better maintained. The packing section was able to align better with upstream production, improving overall workflow efficiency.