The appetite for healthy snacks is growing. More and more consumers are reaching for nuts to satisfy small cravings and boost their energy levels. According to market experts, global sales of nuts are expected to rise from €61.02 billion in 2024 to €78.62 billion by 2029. For manufacturers, this means they must find ways to meet varying regional preferences while keeping production efficient. Dutch contract manufacturer Snack Connection is more than ready to meet this challenge thanks to the support of Syntegon.

In their latest joint project, the two partners combined an existing SVE 2520 DZ vertical bagger with the Elematic 2001 wrap-around case packer.

The result: Snack Connection has not only increased the flexibility and efficiency of its production but also laid the foundation for future projects.

Snack Connection specialises in sourcing, processing, blending, and packaging nuts, kernels, and seeds for the European market. From its production facilities in the Netherlands, the company supplies high-quality products tailored to the specific needs of various regional markets. German and Eastern European discounters, for example, prefer shelf-ready cartons with simple trays or tray-and-hood formats to present assorted nut snacks on supermarket shelves. Dutch retailers, on the other hand, more often opt for single-variety cartons that reflect local consumption habits.

To handle these different requirements, flexibility is at the heart of Snack Connection’s operations, as Kees Pieter van Vloten, Operations Director at Snack Connection, explains: “As a private label manufacturer, we need to handle a variety of products in different formats, so flexibility is essential for us. In addition, we rely on efficient equipment. Most of our customers are discounters, so keeping our production cost-efficient is how we keep our competitive advantage.” By 2022, however, the company faced a significant challenge: they realised they had outgrown some of their case packing equipment. Its stand-alone case packer had become a bottleneck, struggling to keep pace with evolving production needs and prompted Snack Connection to seek a new solution. Having already experienced the reliability and performance of four Syntegon SVE 2520 DZ vertical baggers at their site in Giessen, Netherlands, the team looked no further than Syntegon for support. “Our old stand-alone case packer, which we had purchased from a competitor, offered neither the flexibility nor the speed we were looking for,” recalls van Vloten. “The solution was closer than we thought, really: We decided to build off our existing equipment and partner with Syntegon again. From past projects we knew that we could benefit from their system competence and their proven technologies as well as rely on their service team, who is always available when we need support.”

After successful discussions, Syntegon and Snack Connection came up with a straight-forward and effective solution: They integrated one of the existing SVE vertical baggers with an alignment unit and an Elematic 2001 WA case packer, creating a robust and efficient line solution that ensured seamless communication between all components. The newest project built on the success of previous collaborations: “We were already familiar with the customer’s requirements and knew that we could always rely on open communication between our teams,” says Erik Schipper, Area Sales Manager Netherlands at Syntegon. The project moved swiftly from concept to implementation. From the initial meeting to the finalisation of the purchase order, the process took just seven months a testament to the seamless collaboration between the two teams.

Once it was set up, the new packaging line delivered immediate benefits. The Elematic 2001 WA automated case packing tasks that were previously performed manually, allowing Snack Connection to pack 8 to 16 pillow bags or Doy Zip bags standing up-right into one of four different wrap-around formats. Depending on the configuration, the machine achieves speeds of up to 40 cases per minute a significant increase compared to the previous solution. In addition to improving efficiency and speed, the new Elematic also streamlined warehouse management. By reducing the number of required case formats to just four, the Elematic eliminated the need for extensive storage space, cutting associated costs. Furthermore, the machine’s design minimises material usage, contributing to sustainable operation.

One of the most striking features of the Elematic 2001 WA and responsible for the improvement in efficiency, is its plug-and-play changeover concept, which allows operators to switch between formats without the need for tools. Step-by-step instructions displayed on the HMI guide them through each process step. Integrated sensors and signals alert them to any irregularities along the way and ensure every adjustment is made accurately, reducing the potential for errors and further streamlining operations. “Our new changeover processes were key in futureproofing our production. It has also helped us to reduce the number of skilled operators per shift a real advantage in the food industry, where fluctuation numbers are high and skilled labor is not always easy to find,” emphasises van Vloten.

Since well-trained personnel are key to smooth operations, Syntegon and Snack Connection placed great emphasis on operator training. The shift supervisor took part in the Factory Acceptance Test to gain hands-on experience. During installation, a Syntegon technician stayed on site for three weeks, overseeing machine start-up and training the operators on format changeovers. This ensured that the team could make optimal use of the new equipment from day one.

The company is currently exploring the option of adding an Elematic 3001 WA a larger case packer capable of handling an even wider range of packaging formats. This strategic investment aims to keep pace with constantly evolving market trends.