Next-generation machinery is transforming confectionery production, blending automation with sustainability to meet the demands of a modern market. Kiran Grewal reports.

Across Europe, manufacturers are embracing next-generation machinery that is transforming how sweet treats are made, packaged, and delivered. From the historic streets of Bologna, where Dino Corsini has automated its operations with groundbreaking Agriflex systems, to the state-of-the-art facilities of ULMA Packaging and Schubert, these innovations are setting new benchmarks for efficiency, sustainability, and scalability. This is the story of how cutting-edge technology is reshaping an age-old craft—bringing the confectionery industry into a bold, exciting future. 

In the heart of Bologna, Italy, Dino Corsini, a renowned confectionery producer, has taken a bold step into the future of manufacturing. At the centre of this transformation is cutting-edge technology from Agriflex, a leader in next-generation confectionery machinery. This collaboration has not only automated Dino Corsini’s production processes but also redefined efficiency and sustainability in the industry. 

At the core of the upgraded facility is a highly customised system designed to streamline ingredient handling. Raw materials such as sugar and flour are directed into silos via an external loading system, while oil is stored in specialised tanks. The plant is equipped to manage a variety of macro, midi, and micro ingredients, both in powder and liquid forms, integrating them seamlessly into the production line. 

For Dino Corsini’s CEO, Jacopo Malacarne, the move to automation was driven by a pressing need to replace labor-intensive manual feeding processes. “Apart from sugar, flour, and oil, everything else was manually fed,” Jacopo explains. Over the past two to three years, the company has progressively adopted Agriflex solutions, achieving a 90% automation rate in the feeding process. The results speak for themselves: increased production volumes, greater capacity, and improved operational efficiency. 

The benefits of automation extend beyond efficiency. Agriflex’s machinery provides unparalleled visibility into the production process, offering real-time data on ingredient weights, silo capacities, and residue levels. The equipment also enables thorough cleaning of feeding systems, from large silos to smaller ones, even between production cycles. This ensures a hygienic and seamless transition between batches, meeting the stringent standards of Industry 4.0 and 5.0 frameworks. 

The technology has also transformed how Dino Corsini manages disruptions. From identifying non-compliant raw material batches to addressing interruptions, the system allows for rapid analysis and resolution. Depending on the issue, missing ingredients can be manually integrated or the process adjusted automatically, ensuring minimal downtime and consistent quality. 

This partnership with Agriflex has also helped Dino Corsini meet the demands of its large private label clients, including major wholesale retailers and global manufacturers. Automation has reduced the dependency on labor—a critical factor in today’s challenging hiring environment. By minimising the impact of absenteeism, onboarding time, and workforce management, Dino Corsini has been able to scale up production while maintaining reliability. 

The results are remarkable. Production volumes have soared from 40,000 quintals to 100,000 quintals annually. This growth has been particularly evident in the company’s plum-cake line, and expectations are high for a similar impact on their soon-to-be-launched pancake line. “Agriflex has been instrumental in helping us meet market trends and handle large customer orders with ease,” Jacopo remarks. 

Looking ahead, Dino Corsini is setting ambitious goals. Plans are underway to achieve the highest levels of automation in the market, with a focus on reducing energy consumption and minimising waste. Agriflex’s machinery is at the forefront of this vision, addressing the rising demand for scalable, sustainable, and innovative equipment. 

Driving growth with innovation and sustainability 

Despite global challenges in the mechanical engineering sector, manufacturers like Gerhard Schubert GmbH are proving their resilience, delivering innovation-driven growth and shaping the future of confectionery packaging. With significant investments in digitalisation, robotics, and eco-friendly solutions, Schubert’s efforts highlight a transformative shift in the industry. 

Amid turbulent market conditions, Gerhard Schubert GmbH achieved remarkable growth in 2023, with an overall performance of €320 million and a turnover increase of more than 9%. The German packaging machine manufacturer attributes this success to its long-term strategies, particularly its Mission Blue Sustainability Initiative, which prioritises environmentally friendly packaging technologies. The company’s recent €400 million investment in expanding its headquarters stands as a testament to this vision, offering state-of-the-art production and office facilities designed for both energy efficiency and employee satisfaction. 

“Our Vision 2050 and Mission Blue initiatives are without a doubt the right forward-looking strategies for Schubert. We have defied the trend and achieved a very good annual result. It’s a team effort we can be proud of,” says Marcel Kiessling, Managing Director Sales and Service at Gerhard Schubert GmbH. 

Schubert’s dedication to innovation is evident in its largest single budget allocation—research and development—which represents 9% of its overall performance for 2024. This investment fuels advancements like the TLM Comfort Feeder and Dotlock technology, which eliminate the need for hot glue in cardboard packaging. Other cutting-edge developments include the tog.519 collaborative robot, enhanced robot path-planning systems, and sustainable packaging solutions through the Schubert Packaging Perspectives services. 

The completion of a new assembly hall and office complex has significantly increased production capacity, adding 30% more space for final assembly and workspaces for 300 employees. The complex’s design fosters creative collaboration, while its climate-neutral operation—with features like an ice storage system and rooftop photovoltaics—reflects Schubert’s ambitious environmental goals. 

“With our Mission Blue Sustainability Initiative, we have set ourselves very ambitious environmental protection targets. We are delighted that we have come a step closer to achieving these goals with the new buildings,” says Gerald Schubert, Shareholder of the Schubert Group and Managing Director of Schubert Business Development GmbH. 

Sustainable growth and international expansion 

Schubert’s strategy for sustainable growth hinges on internationalisation, with 83% of its 2023 performance derived from exports. The company is expanding its North American site in Charlotte, North Carolina, to enhance its presence in the region, including a new 2,000-square-metre assembly hall, a larger office building with a training centre, and tailored service offerings. 

“Continued growth is only possible in the long term through the further internationalisation of our business activities,” explains Marcel Kiessling. 

This focus on international expansion is balanced by a strong commitment to innovation at home. Schubert maintains a high in-house production rate of 53%, supported by subsidiaries like Schubert Fertigungstechnik GmbH, which manufactures mechanical components using 3D printing, and Schubert System Elektronik GmbH, which supplies electronic components. Together, these facilities enable Schubert to mitigate supply chain disruptions and maintain quality. 

Schubert produces approximately 140 packaging machines annually, two-thirds of which serve the food and confectionery sectors. With sustained growth for 13 consecutive years and a clear focus on digitalisation, automation, and sustainability, the company is well-positioned to lead the confectionery machinery industry into the future. 

“Our goal of building cost-effective machines and systems of the highest quality for our customers requires continuous investment in effective production and assembly methods, which we are constantly reviewing and improving,” notes Ralf Schubert, Managing Partner and Head of Technology. 

Ambitious targets for a sustainable tomorrow 

While Schubert focuses on cutting-edge robotics, energy-efficient manufacturing, and digitalisation, Syntegon has carved its path through validated climate targets and resource-efficient technologies. Both companies share a clear vision: to advance the global packaging and processing industry with a commitment to sustainable practices that benefit both the planet and their customers. 

Syntegon’s achievements in climate responsibility reflect many parallels with Schubert’s Mission Blue initiative, showing how the industry is aligning with broader global objectives, such as the 1.5°C target of the Paris Agreement. With sustainability becoming a cornerstone of their business strategies, these manufacturers are setting new benchmarks for the confectionery machinery industry. 

Sustainability is no longer an optional pursuit—it is essential to the future of the industry. By aligning its goals with the global 1.5°C target, Syntegon is demonstrating how confectionery machinery manufacturers can combine environmental responsibility with cutting-edge innovation. With the Science Based Targets initiative (SBTi) officially validating its climate targets, the company is advancing its mission to redefine sustainability standards in packaging and processing. 

Syntegon’s validated climate strategy is built on bold and measurable goals. By 2030, the company aims to reduce its Scope 1 and 2 emissions—those generated directly from owned and controlled sources, such as heating fuel, and indirectly from purchased energy—by 48.3% compared to 2019 levels. 

The ambition extends even further to Scope 3 emissions, which account for 95% of Syntegon’s total emissions. These emissions, stemming largely from the operation of its machines at customer sites, will be reduced by 25% compared to 2022. As Steffen Carbon, coordinator for development methods at Syntegon, explains, achieving this target involves forward-thinking strategies: “This is an ambitious goal, as our machines are designed for a long lifespan and we need to plan well into the future. By establishing long-term partnerships with our customers, we support them on their way to more sustainability—with newly developed, resource-efficient technologies and lifecycle services.” 

Real reductions, tangible results 

While many companies rely on carbon offsets to meet their sustainability objectives, Syntegon is taking a different approach. The company is committed to achieving real reductions in greenhouse gas emissions, focusing on practical, impactful changes to its operations and supply chain. 

Reducing energy consumption is central to Syntegon’s strategy. By designing machines that are more energy-efficient, Syntegon not only lowers emissions but also reduces the operating costs for its customers—a crucial factor in today’s competitive market. 

Sustainability extends beyond machinery design to Syntegon’s entire supply chain. The company is integrating environmentally friendly materials, such as green steel, and adopting renewable energy sources for its production processes. This holistic approach ensures that sustainability is embedded at every stage, from manufacturing to the final product. 

“Thanks to our comprehensive goals, we are a reliable partner for customers who also set high standards for sustainability and increasingly expect the same from their suppliers,” says Torsten Türling, CEO of the Syntegon Group. “We share their values and actively support them in implementing a future-proof sustainability strategy.” 

Transforming packaging efficiency at Bon Bon’s Wholesale 

On the factory floor, the future of confectionery machinery is being shaped by technological advancements like ULMA Packaging’s FR200 Flow Pack machine, which was recently installed at Bon Bon’s Wholesale, a leading provider of luxury confectionery and snacks. This new addition has revolutionised Bon Bon’s operations, addressing production bottlenecks and inefficiencies while enhancing product quality and scalability. 

Founded in 2007 and headquartered in the Yorkshire town of Tockwith, Bon Bon’s Wholesale has built a reputation for offering high-quality, exclusive confectionery products to independent retailers. By combining exceptional products with attractive fixtures and merchandising strategies, the company delivers a comprehensive solution that helps retailers stand out from mainstream competition. However, as Bon Bon’s business scaled rapidly, so too did the operational hurdles that threatened to limit its growth. 

The rapid expansion of Bon Bon’s highlighted several inefficiencies in its packaging process. Production bottlenecks, compounded by the labour-intensive nature of chocolate manufacturing, made it increasingly difficult to meet growing demand. Rising labour costs and a reliance on manual processes introduced a higher risk of human error, while the lack of flexibility in existing machinery meant the company struggled to accommodate the variety of packaging formats required for its diverse product range. 

Recognising the need for a more efficient, scalable solution, Bon Bon’s turned to ULMA Packaging and its next-generation FR200 Flow Pack machine. This move marked a turning point for the company, unlocking new levels of speed, precision, and flexibility. 

ULMA’s FR200 Flow Pack machine was the ideal answer to Bon Bon’s challenges. Designed with advanced technology, the FR200 brought immediate improvements to the company’s operations. Capable of high-speed, efficient packaging, the machine significantly reduced production bottlenecks, allowing Bon Bon’s to scale its operations to meet increasing demand. 

Precision and uniformity in packaging were other key benefits of the FR200, ensuring that Bon Bon’s luxury confectionery products reached customers in pristine condition. By automating the packaging process, the FR200 also minimised manual intervention, enabling the company to re-deploy labour into other critical areas of production, such as chocolate manufacturing. 

“The FR200 has transformed our packaging process, allowing us to meet growing demand while maintaining the high quality our customers expect,” says Kirsty Firth, Joint Managing Director of Bon Bon’s. “The flexibility and efficiency of the machine have been game-changers for our operations.” 

The FR200’s versatility was particularly impactful. Its design allows it to handle a wide variety of packaging formats and sizes, making it a perfect fit for Bon Bon’s diverse product offerings. This flexibility ensures the company can adapt to market demands and product innovations without being constrained by its machinery. 

The installation of ULMA Packaging’s FR200 Flow Pack machine has propelled Bon Bon’s into the next generation of confectionery production. By addressing its operational challenges head-on, the company has positioned itself for sustained growth and success. 

Some of the standout benefits of the FR200 include: 

  • Increased Production Efficiency: The high-speed automation of the FR200 has eliminated bottlenecks, enabling Bon Bon’s to handle larger production volumes with ease. 
  • Enhanced Product Quality: Precise, uniform packaging ensures that each product meets the high standards Bon Bon’s customers expect. 
  • Labour Re-Deployment: By reducing the need for manual packaging, Bon Bon’s has been able to allocate more resources to chocolate production, further boosting productivity. 
  • Flexibility and Scalability: The machine’s ability to accommodate various packaging formats supports Bon Bon’s diverse product range and prepares the company for future expansion. 

With the confectionery industry embracing cutting-edge technologies, companies like Bon Bon’s Wholesale and Dino Corsini demonstrate the transformative power of automation and sustainability-focused innovation. These advancements not only address operational challenges but also position manufacturers to thrive in an evolving marketplace, setting a bold precedent for the future of confectionery production. 

Editorial contact:
Editor: Kiran Grewal kgrewal@kennedys.co.uk