August 13, 2009
Innovation and Automation Are Integral Elements to Wolfgang�s Current and Future Growth Opportunities
Wolfgang Candy Company, Inc.
Press Contact: Mike Schmid
Managing Partner - Marketing
Phone: 717.324.6296
E-mail: [email protected]
FOR IMMEDIATE RELEASE
Innovation and Automation Are Integral Elements to Wolfgang�s Current and Future Growth Opportunities
York, Pennsylvania. (August 13, 2009) This summer, Wolfgang Candy Company welcomed �Lucy� and �Ethel� to its Chocolate Factory in York, Pennsylvania, where innovation and automation are integral in growing the company beyond its traditional sales channels. The 88-year-old candy manufacturer needed to accommodate increased volume required by their growing contract and private-label production, up significantly in the last year, so Wolfgang management decided that the time was right to install a new automated tray-packing line�which includes robots affectionately named �Lucy� and �Ethel� reminiscent of the 1952 �Job Switching� (Episode 39) of I Love Lucy.
Wolfgang�s new manufacturing line will be unveiled at a special preview event, �An Adventure in Automation,� at 11:00 o�clock in the morning on Wednesday, August 19, 2009, at company headquarters in York at 50 East 4th Avenue. Wolfgang managing partner and chief marketing officer, Mike Schmid, says, �Fully-automating one of our high-speed manufacturing lines is one of our most powerful advancements facilitating Wolfgang�s growth since building our new facilities in 1985. This combination of manufacturing technologies will enable Wolfgang to package Wolfgang branded, contract and private label confections at capacities that far exceed our past production capabilities.�
It�s not man vs. the machine
Wolfgang management is quick to explain that robots have not replaced human talent in their operations. In addition to installing the automated line this summer, Wolfgang hired over 40 employees who assist in producing contracted confections in other areas of the plant.
With fourth generation family leaders at the helm since 2003, Wolfgang has continued to expand beyond its traditional fundraising product sales, adding contract and private-label packaging, as well as production and packaging of its own brand of chocolate and non-chocolate confections for retail sale. Wolfgang�s 100,000-sq-ft operation, within three buildings in a one-block radius, now produces close to 120 different SKUs on 14 lines.
�With our contract and private label business steadily increasing, we knew it was imperative to consider an automated line. This solution needed to gently handle a range of product types�from well-defined, molded candy pieces to candy bars, both with inclusions and plain chocolate bars, to molded plaques, such as Easter Bunnies and Santa figures,� shared Schmid. �Although human skill is crucial for meeting customer needs in many instances of our business,� he continued, �installing an automated manufacturing solution will help position Wolfgang for the increasing demand for chocolates and other snack food confections.�
"Improvements that enhance manufacturing capacity are typical of creative multi-generational family candy companies�the lifeblood of the confectionery industry,� said Larry Graham, president, National Confectioners' Association (www.candyusa.com). He continued, �The confectionery industry continues to grow even in these difficult economic times. Companies like Wolfgang Candy Company provide small pleasures and inexpensive indulgences, and that never goes out of style."
James McCarthy, CEO and president of the Snack Food Association (www.sfa.org), an international trade association, contributed, "The snack industry congratulates Wolfgang Candy Company on the introduction of its new automated packing line. The Wolfgang Company's commitment to excellence in production and its dedication to innovation are reasons why it continues to have a loyal following of customers through the many generations it has been in the industry.�
The man behind the machine
�Robert L. Wolfgang III, managing partner, Food Safety and Quality, was instrumental in spearheading the project team to identify the optimal solution for managing Wolfgang�s increasing production,� said Benjamin McGlaughlin, president and CEO of Wolfgang Candy Company. �We needed a solution that would fit our available footprint, meet our increased capacity needs and deliver a strong return on our investment,� McGlaughlin said. �Rob and the project team worked diligently to accomplish the objectives and to ensure that installation was timely and complete.�
Rob Wolfgang is enthusiastic about the customizable potential offered by the innovative manufacturing line, specified and integrated by JLS Automation (www.jlsautomation.com). �Another expectation for the robot,� explained Wolfgang, �was speed.� He continued, �We needed a system that could meet or exceed 200 pieces per minute. JLS has given us both flexibility and speed, because it is a pick-and-place system and not a dedicated, hard-engineered system. We can pick-and-place nearly anything, which gives us tremendous flexibility to deliver customized product solutions for existing and future customers.�
JLS Automation�s president, Craig Souser, said, "We recognized many parallels in the challenges facing Wolfgang to those of JLS. In our business, larger competitors dominate the market, forcing us to be innovative and creative to succeed and thrive. Given this "common ground," we found the Wolfgang team to be very open to collaborating with us in designing the right packaging system for their operation. In the development of the system, we learned how important flexibility is to Wolfgang. During the execution of the project, a new product configuration was introduced and was easily accommodated by the "agile" nature of the JLS design."
Automation in action�the way the cookie (won�t) crumble
The new automated line includes a tray denester/placer from FEMC (www.femc.com), a Carrera horizontal wrapper from Ilapack (www.ilapack.com), and the JLS Talon Series dual-robot packaging system. The Talon features two IRB 340 FlexPicker� robots from ABB Robotics (www.abb.com). These two top-mounted robots inspect, pick and place products into thermoform trays with high accuracy and reliability, functioning completely opposite to the robots� namesakes� inefficient madcap pair from I Love Lucy.
John Stough of Graybill Machines, Inc., described how his company helped Wolfgang to continue producing moulded chocolates, while adding additional functionality to moulding chocolates on various sizes of cookies. He shared, �Wolfgang Candy wanted to produce moulded chocolates on cookie bottoms. Wolfgang, knowing Graybill Machines through previous projects, approached us to provide specialized cookie feeding equipment. After a thorough assessment, it was jointly determined that the new cookie bottomed chocolates could be produced by fitting custom cookie feeding equipment to an existing moulding line. Since this is a multi-product line, the capability to make all current chocolates needed to be maintained. Both round and rectangular cookies are fed to the moulds depending on the shape of the chocolates. Wolfgang now has unique capabilities for producing moulded chocolates on cookie bottoms automatically. This adds to their growing range of chocolate product capabilities and allows new market opportunities. �
Stough continued, �Graybill Machines is pleased to continue participating in Wolfgang�s growing range of unique capabilities by providing this specialized cookie feeding equipment. A large part of our business is providing specialized equipment to our customers for their unique products.�
Wolfgang�s project was interesting in that they required a system to wrap all products in a limited space due to the plant layout. These points were critical to Wolfgang if they are going to be able to compete against their larger competitors,� said Michael Amoroso, NE Region sales manager - HFFS Division of Ilapak, Inc.
Amoroso explained, �Ilapak supplied a Carrera 2000 PC flow wrapper to handle a range of products with and without a tray. One of the products in a tray required a speed of one pack per minute, yet another product, a single chocolate medallion, required a packaging speed of 200 packs per minute. We were able to do this because of our modular wrapper design consisting of a quick change sealing head to accommodate the various product sizes and speeds that Wolfgang required. The Ilapak Carrera series flow wrappers are controlled by an industrial PC with servo motor motion control.�
The new line is currently running three types of Wolfgang�s latest line of cookies, EVES � containing a molded piece of chocolate in the center. After the cookies are produced, they are delivered by conveyor to the JLS system. Product is conveyed at constant speed through an existing metal detector and then onto the robotic-picking belt.
On the picking conveyor, product location is identified with a camera, and each cookie is analyzed to check that the top surface is covered with chocolate. Product that passes inspection continues on the picking line. Operating on-demand, the tray denester provides a tray to each wrapper flight. Tray presence is verified with a sensor. The robots then pick each cookie with vacuum technology developed by JLS and place them individually into a tray on the flow-wrapper in-feed conveyor. The flow wrapper operates intermittently and ensures that all trays are completely filled via communication with the robot software before trays leaving the robotic work cell.
Future capacity for growth is sweet
Congressman Todd Platts, pleased that a longtime York business is growing, said, �Wolfgang Candy Company�s strategic investment in this new automated system, as well as their recent additions to their workforce, will help strengthen our community and bolster economic development in York County and the region.�
Benjamin McGlaughlin is thrilled that Wolfgang is thriving when so many companies are facing cutbacks and closures. He attributes Wolfgang�s success to having access to York�s skilled workforce and making strategic decisions at the right time�such as purchasing the new automated system. McGlaughlin believes the return on investment for the new system will be realized within a short period of time, saying, �Our Lucy and Ethel are proving to be a reliable, efficient addition to the Wolfgang workforce. They join a skilled group of operators dedicated to making the highest quality chocolates, confections and snack foods you will ever taste!�
Click to view a photo of �Lucy and Ethel� in action.
ABOUT WOLFGANG CANDY COMPANY
Founded in 1921, Wolfgang is one of the oldest family-owned and managed confectionery manufacturers in the United States. From peanut brittle to hollow chocolates, Wolfgang offers one of the most extensive arrays of high-quality chocolates and non-chocolate confections available in the marketplace. In addition to the all-natural dark chocolate dipped Raspberries, Blueberries and Cranberries, some of the company�s most popular products include chocolate topped truffle cookies, a wide assortment of solid and hollow molded chocolates � bunnies at Easter and Santa at Christmas, and fine boxed chocolates � chocolate-covered pretzels and animal crackers, chocolate-covered peanut butter marshmallow treats (marshmallow and peanut butter covered in milk or dark chocolate), hand-dipped raisin and peanut clusters, and other assorted milk and dark chocolates.
Wolfgang markets and distributes its products through retail, wholesale (private labeling and contract manufacturing), and fundraising sectors. The company is a market leader in the fundraising industry and a trusted name enabling organizations of any size to achieve their financial goals. With a sole focus on and commitment to its customers, Wolfgang demands unparalleled quality in its products, providing its customers with a truly enchanting experience in taste.