Jan 6 2012 --- The hermetically-sealed Overlap Seal double-twist wrappers from GEA CFS Weert not only keep the lollipop dry in high humidity conditions but also offer up to a 30% saving in film compared to a regular bunch wrapper. And with the recently added ‘Easy Open’ tear slit feature, lollipops wrapped this way are even easier to open than the regular double-twist. When running on the company’s recently upgraded TwistWrapper machine, a wrapping capacity of up to 1,000 ball lollipops per minute is possible.

Hermitically sealed wrapper extends the lollipop’s shelf life

Unlike regular lollipop double-twist wrappers, which allow moisture to reach the lollipop, the patented Overlap Seal double-twist wrapper is hermetically sealed. In regions where atmospheric humidity is high, moisture in the air can significantly reduce the shelf-life of a lollipop if it is not hermetically sealed. In the past, overcoming this problem meant using either a bunch-wrap that is twisted and sealed around the stick only, or using a flow-wrap where the whole lollipop is sealed in on all sides – including the stick. The hermetically sealed Double-Twist with OverlapSeal reduces costs by using much less film than a bunch-wrap and looks good. And of course for the consumer, the patented EasyOpen slit takes all the fiddly finger work out of opening the candy. Kees Le Loux, Segment Manager for Lollipops, said, “In combination with the excellent hermetic sealing qualities, the new Easy Open tear slit makes this wrapper even easier to open than a regular double-twist, and I am confident it is set to become a new industry standard."

A revolution in designing rotating machines

There is more to this story than an innovative wrapper style. The CFS Aquarius TwistWrapper machine for applying the double-twist wraps up to 1000 lollipops per minute incorporates innovative technology that has each lollipop visit 10 heat-sealing stations! To reduce the complexity and increase reliability, GEA CFS Weert replaced ‘wired’ electrical heating elements in the sealing stations with wireless inductive heating, and each lollipop spends just 30 milliseconds at each sealing station. This heating system with contactless transfer of energy seals around the stick with consistent sealing quality. Wrapping options for the CFS Aquarius double-twist wrapper include heat-sealable polypropylene, laminate and cellophane films and wax paper, all in single or double layers.

Available as option and field upgrade

In addition to being available as an option on new machines, existing CFS Aquarius TwistWrapper machines (after a certain date) can also be upgraded for the Overlap Seal double-twist wrappers. The TwistWrapper is a continuous wrapping machine that handles lollipop diameters from 18 to 35 mm and accommodates film reels up to 440 mm diameter. It achieves its high speed through smooth film handling, precise cutting and automatic feeding.

The left-handed FlexFormer is a win-win solution

A simple yet thoughtful development of the CFS Aquarius FlexFormer is to make it available in a lefthanded configuration as well as the standard right-handed machine. This means that instead of working with two operators, lollipop manufacturers can run two FlexFormer machines (including batch rollers and rope sizers) with just one operator. When running shifts, this brings considerable savings in personnel costs. Another benefit is that it has a positive effect of the factory layout as with a right- and left-handed FlexFormer pair, quite some space can be saved in the production area.

Forming ball, flat and 3D lollipops

Naturally, the left-handed machine has all the features and benefits as the right-handed FlexFormer, giving excellent flexibility and speed in lollipop forming. It can form ball, flat or 3D lollipops – with center filling as an option – while still achieving the highest speeds. On the smaller range of lollipops, it runs at over 2,000 lollipops per minute, a figure higher than most dedicated ball lollipop forming machines.

Adding value and branding opportunities

Kees Le Loux comments, “There have been other attempts to combine formats on a single machine, but not so comprehensively or with the same degree of flexibility as our FlexFormer. And we are certainly the first to produce a machine which brings all of this together with such high outputs. Our customers can now produce 3D or ‘fancy’ lollipops with a centre filling on the same machine.” If the viscosity of the filling is close to that of the candy mass, machine speeds could still top the 2,000 per minute mark. This flexibility means manufacturers already producing shaped lollipops will be able to make their lollipop ranges stand-out from the crowd. The combination of much greater flexibility with considerably higher outputs is all based on the proven principles of the industry’s standard ball lollipop forming machine.

Material and labour saving features

The FlexFormer incorporates more material and labour cost saving features, such as an automatic stick brake in combination with sugar rope detection to ensure that if there is no sugar rope, it automatically stops feeding sticks - reducing waste to a bare minimum. A level sensor in the stick hopper also prewarns the operator when the quantity of sticks in the hopper needs to be increased for continuous operation.

Proven engineering for extremely high reliability

Given the high operating speeds, GEA CFS Weert has also gone to great lengths to ensure that the mechanical parts are well protected. Inside the closed machine housing there is an effective autolubrication system, minimizing maintenance needs and downtime. Most of the mechanical components are in closed compartments, reducing both wear of these parts as well minimizing the required cleaning time. A Clean-In-Place (CIP – available as option) automatically cleans the die set with warm water and after a visual inspection, also automatically dry and lubricate the die set.