Things are going sweetly at Maestrani Schweizer Schokoladen AG, and recently, the chocolate manufacturer has also become much more efficient: the long-established company in Eastern Switzerland has set the course for more powerful and precise packaging of its popular Minor chocolate products. Together with ITECH and Ishida, it implemented a modern packaging system that raises speed, accuracy, and ergonomics to a new level, all in line with sustainable growth.
Facts and figures
- Maestrani invested in a new Ishida multihead weigher to increase speed and efficiency and reduce waste
- The Ishida weigher can handle chocolate pieces weighing from 5g to 22g at typically 40 packs per minute
- The Ishida multihead has been enclosed to reduce noise level to well below 85 dB
- A key factor in the successful installation was the close partnership with Ishida’s local distributor, ITECH AG
Challenge
The multihead weigher Maestrani previously used no longer met requirements, its accuracy was declining, and the line was increasingly becoming a bottleneck in production. “The old weigher was simply too inaccurate and could no longer meet our throughput rates,” recalls André Pfister, Production Manager at Maestrani. Replacement was essential, especially given the rapidly growing volume: Around 4,500 tons of chocolate leave the Flawil factory annually, and that figure is rising for the confectionery producer.
Solution
After a careful evaluation phase, the company chose an Ishida 14-head multihead weigher, supplied and installed by Ishida’s local distributor, ITECH AG.
“The collaboration with ITECH was very smooth, from planning and testing with original product samples to final commissioning,” said Pfister.
The new Ishida weigher works in conjunction with an existing VFFS bagmaker and has been optimised for a wide variety of formats: from 110g stand-up pouches to 1kg pillow packs and cans. The smallest chocolate pieces weigh just 5g, including the well-known “Minerli” chocolate bars, while large chocolate figures weigh up to 22g.
A key factor in the company’s success is the close partnership with Ishida, whose reliable and internationally proven technology forms the basis for every ITECH solution.
Results
The use of the new Ishida multihead weigher delivered Maestrani a number of benefits:
- Increased speed: Depending on the pack format, the targeted 40 packs per minute are either met or exceeded
- Greater accuracy: More precise dosing, lower raw material consumption
- Reduced waste: Fewer damaged or incorrectly wrapped products
- Ergonomic operation: The Ishida weigher has been enclosed to reduce noise levels in production to well below the 85 DB limit
Fast training and operator competence: Operators and engineers have received comprehensive training and are now able to generate new presets and make fine adjustments, according to Maestrani this has been a real benefit for operational efficiency.
“We are very satisfied with the solution and would work with ITECH and Ishida again at any time,” Pfister said.
Pfister particularly praised the collaborative and goal-driven project management, which addressed all their requirements. The technical support is also impressive: “We know we can reach someone around the clock, which gives us real peace of mind,” said Pfister.
“Reach out to ITECH with clear requirements, and the implementation will be perfect. This collaboration is an example of how precise planning, close collaboration, and technical expertise enable sustainable weighing and packaging solutions production, in keeping with the spirit of genuine Swiss chocolate quality!”, summarised Pfister.
