Schubert North America LLC  

Charlotte,  NC 
United States
http://www.schubert.group
  • Booth: 7303

Schubert is a global leader in top-loading packaging machines (TLM). For its digital, robot-based packaging machines, the family-owned company, headquartered in Germany, builds on an interplay of simple mechanics, intelligent control technology and high modularity. With this philosophy and a highly developed culture of innovation the company has been pursuing an entirely independent technological path for more than 50 years. The second generation of the company now employs 1,300 people. Innovations include the vision control system, the transport robot Transmodul or the flow-wrapping machine Flowmodul. Schubert provides future-proof solutions that are easy to operate, flexible in terms of format conversion, high in performance and stable in function. The machines package products of all types in trays, cartons, boxes or flow-wrap bags. 

With the new Schubert lightline machine series, customers can master standardized packaging tasks with great efficiency and high quality - at attractive purchase costs and short delivery times. It consists of three machine types: The lightline Cartonpacker, the lightline Pickerline and the lightline Flowpacker.

Space-saving design, unbeatable efficiency and excellent quality control are the hallmarks of the Schubert Flowpacker. It can be equipped with four different sealing technologies. The new patented technology makes it possible to program sealing to the millisecond and ensures constant sealing times. For each flow-pack, the cross-sealing unit immediately adapts to the variable speed of our upstream pick & place robots. Like all of Schubert’s sealing technologies, the flying cross-sealing unit can be integrated into every Flowmodul and combined with other sealing technologies. 

All Schubert TLM machines can be connected to the new GRIPS.world digital platform. The result: Predictive Maintenance for more line availability and long-term investment security.
By establishing its North American headquarters in Charlotte, North Carolina, and with sites in Dallas, Texas and Toronto, Ontario, Schubert is expanding its customer support across the continent. This support encompasses high-level accessibility, preventive service as well as extensive training for customers. Schubert has installed two training machines at its training center in Charlotte. 


 Videos

Injection machine and pickerline from Schubert
Schubert Flowmodul with new sealing technology

 Show Specials

  • At its IBIE debut, Schubert chooses to premiere the new lightline Flowpacker on the North American market. The lightline Flowpacker is part of Schubert’s lightline machine series and combines a Pickerline and a Flowmodul in one system. 

    The machine consists of Schubert’s patented state-of-the art sealing technology for packaging heat sensitive products even more gently into flow-packs. 
    The exhibited TLM system is designed for a Canadian manufacturer of baked goods to efficiently automate its end-of-line process by seamlessly integrating the primary and secondary packaging of freshly baked croissants and Danish pastries into one system. 


 Press Releases

  • Heat-sealing film is often a more appropriate solution than cold-sealing – if only the processing aspect were less demanding. For an airtight flowpack with a high-quality seal seam, three factors need to remain constant during the sealing process: temperature, pressure and time. Furthermore, not every product can withstand the heat, which significantly limits flexibility in the packaging process. This is a clear case for new creative ideas from Schubert.

    Heat-sealing has a number of advantages: heat-sealing film is cost-effective, can be stored for long periods of time and leaves no unpleasant adhesive residue behind when the packaging is opened. But how can Schubert customers benefit from these advantages? This was our incentive to produce a new heat-sealing technology.

    The first challenge – heat-sensitive products such as chocolate, which can be damaged on the longitudinal sealing unit – was solved by Schubert using ultrasonic sealing technology. This means that unlike standard heat-sealing technology, the heat is generated in the heat-sealing film itself and does not dissipate into the tools and machine parts. The product therefore remains flawless during longitudinal sealing. Ultrasonic technology also ensures that the seal quality remains the same at differing machine speeds. The fixed-mounted cross-sealing unit presents a greater obstacle: the faster the products are channelled into the cross-sealing unit, the shorter the sealing time, and vice versa. Markus Riek, Flowmodul Team Leader, explains: “The challenge was clear: the speed of the chain is variable. How can we keep the sealing time constant?”

    Flying opens up new possibilities

    The key was to break the rigid mechanical link between the chain and the cross-sealing unit, and to design a mobile unit. When the speed of the chain changes, the unit moves either in the running direction or in the opposite direction, allowing each individual flowpack to have the same sealing time. Company founder Gerhard Schubert was immediately impressed and brought in his own ideas: “This needs to be made into a robot.” The flying cross-sealing unit was born.

    The new technology makes it possible to program sealing to the millisecond and ensures constant sealing times. This is because, for each flowpack, the cross-sealing unit immediately adapts to the variable speed of our upstream pick & place robots. Like all of Schubert’s sealing technologies, the flying cross-sealing unit can be integrated into every Flowmodul and combined with other sealing technologies. 

    Facts and figures

    • There are 36 Flowmodul units in use, of which four feature flying cross-sealing technology and eight have ultrasonic sealing technology. Three more have been ordered.
    • They are used to package biscuits, chocolate, marzipan, pancakes and French toast, as well as BFS products from the pharmaceutical industry and many other products.
    • The output is up to 500 packs per minute with a maximum chain speed of 60 metres per minute.
  • For life’s elementary challenges – the Schubert lightline

    Food manufacturers can now rely on a new machine series from Schubert for simple, frequently sought-after packaging tasks. The Schubert lightline offers cost-effective and highly efficient solutions for elementary everyday packaging assignments. The compact lightline machine types cover the entire range of most common packaging requirements. They automate a wide variety of standard packaging tasks at an attractively low investment cost. The machines can be delivery quickly and are ready for use within a very short time.

    With the Schubert lightline series, the German packaging machine manufacturer is addressing packaging tasks that call for less flexibility, at low investment and operating costs. All lightline machine types are preconfigured. This means they are designed for pre-defined product and packaging formats. The machine series provides high-efficiency automation solutions without any compromises: the manufacturer guarantees the same outstanding Schubert quality for lightline machines as it does for its freely configured systems – without sacrificing functionality, durability, user-friendliness and service.

    Three types of machines for all tasks

    With the lightline Cartonpacker, lightline Pickerline and lightline Flowpacker, three high-performance systems are now available that can solve virtually any elementary packaging task for piece products. The new lightline Cartonpacker takes on the role of a classic case packer when erecting, filling and closing cartons. The lightline Pickerline is a pick & place line for picking and placing products into trays. The lightline trio is completed with the Flowpacker, which, in combination with the Pickerline, efficiently packs products in flowpacks.

    Proven Schubert quality

    Each of the three machine types is based on preconfigured TLM modules with intelligent control and the modular machine technology which has made Schubert successful for more than 50 years. Like all packaging systems from Schubert, the new lightline machines also distinguish themselves with outstanding performance, efficiency and reliability over their entire service life. Another advantage of the new machine series is scalability. If additional modules are required, the lightline Pickerline and the lightline Flowpacker can also be adapted to higher output volumes. Customised pick & place tools and four different sealing technologies for packaging in flowpacks guarantee the best possible adaptation to each product.

    Entirely supported by the Schubert Customer Services, all lightline machines offer the same scope of services in terms of system availability and digital connection as all other Schubert machines. In the future, OEE evaluations and preventive service will also be possible via the manufacturer’s GRIPS.world digital machine platform. Customers now have a choice with Schubert: either freely configurable machines that are individually tailored to specific customer requirements – or the new attractively priced lightline machines for simple packaging tasks.

  • Gerhard Schubert GmbH continues its positive growth trend: with an increase in sales of 7.3 per cent and a turnover of 211.5 million euros, the globally recognised market leader in top-loading packaging machines successfully closed its 2018 financial year. For the first time, the manufacturer exceeded the targeted 200 million mark. The Schubert Group also recorded a strong result last year. Compared to the previous year, consolidated group sales increased significantly by 16.4 per cent to a total of 283.9 million euros. This success is not only based on the efforts of 1,332 employees, but also on a consistent growth strategy. Schubert is strengthening its activities in China with the foundation of Schubert Robotics Shanghai, while driving forward future-oriented projects in the realm of digital packaging and the field of robotics.

    Peter Gabriel, Commercial Managing Director of Gerhard Schubert GmbH, is very pleased: “We even slightly exceeded our minimum earnings target of seven per cent on total operating performance.” The company currently employs 936 people at its headquarters in Crailsheim. “In the current year, we are planning further growth to sales of 225 million euros,” Gabriel adds. The group of companies has also set itself new objectives: in 2019 it could even exceed the turnover mark of 300 million euros for the first time. Key factors behind the machine manufacturer’s steady upward trend are favorable developments in international markets and continuous investment in new technologies and innovative packaging solutions.

    A PROMISING START TO THE CURRENT YEAR

    Gabriel assesses the economic outlook for 2019 as positive. “We have a favorable volume of orders. Our range of unprocessed orders is within the target corridor of about six months.” After the first quarter, over 90 per cent of Schubert’s planned annual sales for 2019 are already in the order books. “The very positive development of incoming orders in North America and the renewed strength of Central Europe are also showing encouraging trends,” says Gabriel. The expansion of the service product range and the increase of service personnel also appear to be having a positive effect.

    SCHUBERT NORTH AMERICA DOUBLES ITS TURNOVER
    The subsidiaries also reported consistently positive commercial results. Schubert North America was extraordinarily successful with its headquarters in Charlotte as well as its service and sales offices in Dallas, Texas, and Toronto, Canada. At 77.7 million US dollars, sales in 2018 more than doubled compared to the previous year. Hartmut Siegel, Managing Director of Schubert North America since last year, sees the results as another driving force: “We’re on the right track and are winning more and more customers in the North American market with our highly flexible packaging solutions.” The high level of interest we experienced at the last PackExpo in Chicago – especially from companies in the food industry – promises ongoing positive developments in 2019.

    NEW SUBSIDIARY SCHUBERT ROBOTICS SHANGHAI IN CHINA

    The demand for automated packaging solutions is also high on the other side of the globe: after the USA and France, China is the third largest export market for German food processing and packaging machinery. Schubert has been represented there with its Schubert Robotics Shanghai sales and service location since 2018. Marcel Kiessling, Managing Director of Gerhard Schubert GmbH, reports: “The numerous enquiries and initial orders are already confirming our decision to actively participate in shaping this growth market.”

    Since 2018, Schubert has been represented in China, the third largest export market for German food processing and packaging machinery, with its Schubert Robotics Shanghai sales and service location.

    ENGINEERING EXPERTISE AS A SERVICE IS PAYING OFF

    The Schubert Packaging Systems subsidiary is also indicating positive figures. Under its umbrella, Schubert-Consulting and Turnkey Services provide the company’s consulting and engineering expertise. The Schubert-Pharma and Schubert-Cosmetics areas are also particularly consulting-intensive. The demand for consulting services and turnkey lines is increasing – especially the integration of various packaging processes is of great importance for customers. In 2018, the Schubert experts were successful once again: sales rose from 50.9 million euros in the previous year to 58.9 million euros.

    INNOVATIONS AND INVESTMENTS FOR THE FUTURE

    Schubert again lived up to his reputation as an important driving force in the industry in 2018. One example that offers further growth potential is the new Schubert lightline machine series which was introduced at FachPack. The company will continue to focus on innovation in the future: “We have been investing between eight and ten per cent of annual sales in research and development for decades. And we will continue to do so in the next few years,” highlights Ralf Schubert, Managing Partner of Gerhard Schubert GmbH. The Crailsheim location will also benefit from the many positive developments: “Within the next three years, the company will deploy a volume of close to 30 million euros.” In addition to an education and training centre, another production hall will also be built. “Crailsheim offers the best requisites to remain a strong innovator,” says Ralf Schubert. This potential was reflected in a special award in 2018: Gerhard Schubert GmbH was honoured with the “Factory of the Year” award for its innovative strength, its outstanding quality along the entire value chain and the appreciation it shows its employees.

    Crailsheim is increasingly focusing its efforts on the digital future of packaging technology. This includes the GRIPS.world digital platform which creates a direct digital link between machine, customer, manufacturer and, in the future, suppliers, and which will enable predictive maintenance, among other things. It is decisive that the machines are securely connected, which Schubert ensures with its GS.Gate Edge Computing Gateway. Further development of the so-called digital twin is also important for the company. It will enable the packaging machine to be displayed as a visual 3D model on the GRIPS.world platform and to be moved in real time directly via the machine control data. “In the future, we will be able to significantly accelerate design and delivery,” explains Ralf Schubert. The Schubert experts are also currently working on the further development of 3D printing of machine parts as well as a collaborating robot.

    The Schubert experts are also currently working on the development of a collaborating robot (Cobot).

    MOVING MOMENTS FOR SCHUBERT

    Apart from the commercial figures, 2018 provided Schubert with some inspiring moments. Company founder Gerhard Schubert celebrated his 80th birthday in July. With his approach of solving complex packaging tasks with flexible machines within a modular system, he has been one of the most influential developers in the packaging industry – and still is today. His ideas continue to flow into Schubert’s innovative robots, machines and packaging solutions, which always go a decisive step further.

  • Into the digital future – securely and efficiently

    Crailsheim, April 2018 – By digitally networking production systems, manufacturers can significantly increase their efficiency and availability. With GRIPS.world, packaging machine manufacturer Schubert will soon be offering its customers a digital platform that will significantly improve service and system availability. Beginning in May 2018, all TLM machines from Schubert will be ready to connect to this digital platform upon customer request. In the mid-term, it will open up new opportunities for preventive maintenance and communication with customers. The new GS.Gate gateway, which provides the highest level of protection at sensitive interfaces, ensures optimum security during data exchange.

    The Crailsheim-based company is a pioneer in the engineering and design of digital packaging machines and has been providing important impetus for the development of intelligent machine control systems and automation solutions for many years. Schubert developed the GRIPS.world digital platform in order to be able to offer its customers the full potential of networked machine solutions in the future. As of May 2018, all TLM machines will be able to connect to the platform via the Internet.

    Ensuring high system availability
    With GRIPS.world, customers will soon be able to access TLM system production data from anywhere worldwide. Data sovereignty, of course, lies entirely with the customer. If an intervention by a Schubert service technician is required, remote maintenance can be activated by the customer. With the data collected, predictive maintenance can be used to identify potential problems at an early stage, thereby avoiding downtime and unplanned service calls. In the future, the system will forward error messages or possible causes of an impending failure to the responsible employee, e.g. via mobile devices. This notification will take place even before the actual part wears out, thus avoiding a costly failure. The operator then receives suggestions for remedial action from the program. The objective is to entirely avoid unplanned downtime.

    Optimising overall system effectiveness
    GRIPS.world is an important component of Schubert Customer Services. With the aim of keeping total plant efficiency at the highest possible level over the entire service life of the machines, the performance and deviations from specified target states will be continuously adjusted in the future. The customer will always have an overview of this data via a dashboard and, for example, receive recommendations for increasing production capacity and optimising capacity utilisation. With this information and the results of integrated condition monitoring, customers can increase their productivity and compete more successfully.

    Secure data transfer
    Ensuring data security for its customers is a top priority for Schubert. The basis for networking the TLM machines is therefore a secure machine interface that collects and evaluates operating and process data, making it available for different systems. For this purpose, the subsidiary Schubert System Elektronik has developed the GS.Gate machine gateway in cooperation with genua GmbH, a company of the “Bundesdruckerei” or Federal Printing Office. For secure remote maintenance and data transmission, the industrial gateway is equipped with a firewall that securely encrypts the data obtained and forwards it via the Internet to the respective analysis system or to the cloud. To ensure the highest level of protection between the machine and the external network, the GS.Gate is designed according to the “Security by Design” principle. Data processing applications that are directly connected to the machine are separated from the security systems. This protects the communication and data from access from the external network.

    The GS.Gate is manufacturer-independent and can therefore be connected to different machines. Through a ‘docker’, individual applications can be installed and connected via common interfaces. Important data for the analysis are already filtered out from the status and performance data. The gateway is administrated and maintained remotely through the encrypted connection. Schubert System Elektronik offers customers services for the GS.Gate such as maintenance, complete system management and individual support packages. This allows manufacturers to focus on their production and capitalise on the many benefits of networked production processes.

  • A fully booked conference, a festive awards ceremony and a factory tour in Crailsheim on 21 and 22 March concluded the “Factory of the Year 2018” competition. Gerhard Schubert GmbH was honoured with the overall win by the jurors the very first time it participated in the competition. Gerhard and Ralf Schubert accepted the artistically designed award and highlighted in their presentation how well innovation and standardisation fit together.

    Ludwigsburg, the former royal residence just outside Stuttgart, recently hosted an event that has a special significance for manufacturing companies: the conference and gala for the “Factory of the Year 2018” competition. Gerhard and Ralf Schubert, Managing Directors and Shareholders of Gerhard Schubert GmbH, were delighted on behalf of the entire company to receive the award presented to them by last year's winner Ilkay Ormandy, Plant Manager at P&G Crailsheim. In her laudatory speech, she underscored the passion required to build a business, develop innovative and compelling products, and ultimately succeed. “You can feel this passion when you walk through the company and meet the people working there. Nothing has changed since Gerhard Schubert’s early career!”

    The Schubert team with company founder Gerhard Schubert (1st row, 2nd from left) accepted the “Factory of the Year” award during the festive gala. Image: Süddeutscher Verlag Events

    FROM ZERO TO THE WINNER’S PODIUM

    Gerhard Schubert GmbH participated for the very first time and achieved the overall win for the Crailsheim plant. “At this year’s competition, laureates such as Gerhard Schubert [...] showed that they are able to bring their production to a level of excellence,” said Dr Marc Lakner, Partner and Managing Director at A.T. Kearney, highlighting the performance of the award-winning companies. The eight jurors acknowledged Schubert’s ability to innovate, its quality management throughout the entire value chain and the appreciation it shows to its employees.

    Ralf Schubert, Managing Director and Shareholder of Gerhard Schubert GmbH, gave the 220 conference participants insight into Schubert’s DNA and the interplay between innovation and standardization.

    A CLEAR STRATEGY DRIVES DIGITALISATION FORWARD

    Under the title “Working on the future together, to be successful in the present”, Ralf Schubert gave the 220 conference participants insight into Schubert’s DNA, i.e. its focus on striving for perfection and sustainable solutions as well as the interaction of innovation and standardization. The key building blocks to achieve this are the eight standard components, from which highly flexible solutions to individual customer requirements are created. These include three different robots as well as the Transmodul transport system and image processing systems developed in house. Processes in all departments and areas are defined and continuously improved with the GRIPS process management system. In order to play a pioneering role in all important key technologies, Gerhard Schubert GmbH relies on a clear digitalization strategy.

  • For the first time ever, Gerhard Schubert GmbH took part in the “Factory of the Year 2018” competition and promptly won over the jury: the Crailsheim site was awarded the top prize. The jury was especially impressed with the plant’s innovative capability, the outstanding quality throughout the entire value chain and respectful treatment of employees. The conference of the same name and the awards ceremony scheduled to take place in March 2019 will conclude this year’s competition.

    “We are delighted to be honoured with this prestigious award. We are especially proud that the jury selected us as the overall winner the first time we participated in the competition,” says Jörg Brenner, CFO at Gerhard Schubert GmbH. Actually, the packaging machine manufacturer from Crailsheim was looking for a benchmark to further improve its processes. It has always been intrinsic to the company’s philosophy to set ambitious goals and put things to the test. This applies to its technology as well as to all processes. The “Factory of the Year 2018” acknowledgement confirms that Schubert is on the right track with this strategy. Showing appreciation to employees is very important to the company’s management. The fact that they succeed at this is also reflected in the long-term service of many employees.

    DIGITALISATION STRATEGY

    Explaining their decision, the eight jurors from the areas of business and science highlighted the fact that Schubert thinks ahead in a way that is very innovative, has very high-performance indicators and is driving digitalisation forward with a clear strategy. This is precisely what led to the creation of the TLM packaging machines which have made the family business so successful since its founding in 1966. The project teams, following a modular concept, develop highly flexible solutions that are specifically tailored to the needs of each individual customer. The spectrum of users who rely on the Crailsheim machines ranges from confectionery manufacturers to the pharmaceutical industry to the cosmetics sector.

    SUSTAINABLE QUALITY IMPROVEMENT AS A SUCCESS FACTOR

    Customer benefit is always the first priority for the packaging machine manufacturer. In order to be able to produce high-quality, cost-effective systems for customers, several factors, including materials management, logistics and final assembly, are continuously analysed and optimised. An important factor here is the GRIPS management system – an in-house development, like so much at Schubert. This is the result of working “Together towards innovation, processes and standards” (“Gemeinsam in Richtung Innovation, Prozesse und Standards”) in all areas and departments, as well as a clear digitalization strategy targeted at playing a pioneering role in all important key technologies. This applies to IT systems as well as to production technologies. The machines, which are developed, designed and built by Schubert, are tailored to the customer's specific packaging tasks.

    SUPPLIERS AND EMPLOYEES AS PARTNERS

    The jury saw the close collaboration between Gerhard Schubert GmbH and its suppliers as a further notable strength. “We produce exclusively in Germany, as a matter of conviction, and we rely on long-term partnerships,” asserts Ralf Schubert, Managing Partner at Gerhard Schubert GmbH. “This creates trust and an ideal platform to ensure the flexibility we need.” Employees also make a significant contribution to the company’s success. Close to 850 people now work at this award-winning location. The fact that Schubert offers them an excellent working environment is also reflected in the employees’ length of service. As delighted as everyone may be with the award, for Gerhard Schubert GmbH, the jury’s feedback is an incentive to continue along the chosen path and pursue ongoing improvement in the future. As a matter of conviction, the company has always produced exclusively in Germany. Long-term partnerships with suppliers ensure the necessary flexibility.

    MORE THAN 2,000 SUBMISSIONS IN 27 YEARS

    The “Factory of the Year" competition was initiated in 1992 by the internationally active A.T. Kearney consulting firm in collaboration with the German ‘Produktion’ trade magazine. Since then, up to 100 manufacturing companies have participated in the benchmarking test every year. According to the initiators, it is considered to be the most stringent test in this area. Headquarters in Germany, Austria or Switzerland and a staff of at least 100 are prerequisites for participation. A two-day conference and award ceremony conclude the yearly awards. For the “Factory of the Year 2018”, this will take place on 21 and 22 March 2019 in Ludwigsburg, Germany. Ralf Schubert will give a talk on Gerhard Schubert GmbH’s successful journey. Interested participants will then have an opportunity to experience the plant first-hand during a guided tour in Crailsheim on the second day of the conference.

  • Gerhard Schubert GmbH: Robot technology enables compact machine layout

    Space-saving flow-wrapping with the Flowmodul

    Crailsheim/ProSweets Cologne, January 2019 – A Flowmodul system from Schubert saves up to 70 per cent of floor space compared to a mechanical flow-wrapping machine. The Schubert Flowmodul’s extremely slim machine layout is based on an approach pursued by company founder Gerhard Schubert as early as in the 1980s: robot-assisted packaging processes.

    With the help of robotics, Crailsheim-based packaging machine manufacturer Schubert develops high-performance innovations again and again. An example of this is the Schubert Flowmodul. With this unit, the flow-wrapping process is entirely integrated into a TLM picker line. This enables a machine layout which is exceptionally slim and compact. Compared to a traditional flow-wrapping system with conventional feed, a Flowmodul requires only one third of the footprint. At the same time, the machine’s exceptionally high efficiency of over 99 percent ensures better performance. Since the Flowmodul’s market launch two years ago, 25 companies worldwide have been won over by its many advantages. In addition to the space-saving design and extremely high efficiency, the flow-wrapping component enables effective quality control of the products to be packaged and can be flexibly adapted to a wide variety of requirements. Small batch sizes, frequent product changes and a large variety of products can be realised as well as the packaging of highly sensitive products.

    A quantum leap through robots

    This quantum leap in terms of the compact machine layout was enabled by the use of robots. The pick & place robots in the Flowmodul, with their individually designed tools, carefully place any conceivable product into the flow-wrapping component’s feed system. In contrast to the long feed belts of mechanical systems, processing with these F4 robots is much more gentle and efficient: with no risk of product damage on long feed paths, no rejects due to breakage, no unnecessary contamination of the packaging system.

    Reliable quality control

    Moreover, upstream image processing with a 3D scanner performs the optical quality control of the products to be packaged. It checks position, orientation, shape, colour and volume as per the customer’s specifications. This ensures that only absolutely faultless goods are picked up by the F4 robots and placed into the feed chain. The Flowmodul also offers maximum flexibility in terms of product mix. The robots are able to group and stack even very fragile crackers or biscuits in all possible variations. The interaction between the image processing, the pick & place robots and the integrated flow-wrapping component guarantees a product quality of almost 100 per cent.

    The Schubert Flowmodul is compatible with all standard heat- and cold-sealing films. Thanks to a new cross-sealing unit developed by Schubert, the highly efficient flow-wrapping component now also packs heat-sensitive products, such as chocolate, with the cost-effective and practical heat-sealing technology. And it contributes up to 17 per cent savings in material costs for the film.

  • Combining modularity and flexibility as a model for success

    Gerhard Schubert GmbH from Crailsheim (Baden-Wurttemberg, Germany) produces its digital, robot-based packaging machines with a clear focus on the interplay between simple mechanics, intelligent control technology and a high degree of modularity. This approach soon made Schubert, which was founded in 1966, a globally recognized market leader in top-loading packaging machines. With this philosophy and its own very distinct culture of innovation, the business has been breaking technological ground for over 50 years.

    Schubert’s TLM technology provides the machine manufacturer’s many customers around the world with future-proof, high-performance packaging machine solutions that are easy to operate, functionally stable and highly flexible in terms of adapting to format and product changes. The TLM packaging machines package products of all kinds and from all industries – ranging from food, confectionery, beverages, pharmaceuticals and cosmetics, to technical products – in trays, cartons, boxes, bottles, tubes or flow-wrap bags.

    Modularity as core competence

    Flexibility, efficiency and reliable technology are the cornerstones behind the success of TLM packaging machines from Gerhard Schubert GmbH. The machines’ modular design, along with their advanced mechanical design and intelligent control systems, ensure exceptional effectiveness.

    Today, Schubert’s eight basic modules enable a highly adaptable machine structure, within which all functions, such as feeding, erecting, filling, capping/lidding/sealing, labelling, marking and palletizing can be combined. In addition to Schubert’s VMS control system, the two-, three- and four-axis robots, image recognition systems and the recently introduced Transmodul standard component all come together to form the basis of the TLM machines. Thanks to these rail-based robots, transport tasks can be engineered much more efficiently. At the same time, the Transmodul further increases the compactness of the TLM systems. 

    In 2016, Gerhard Schubert GmbH not only celebrated its 50th anniversary, but also the introduction of a new system component that sets new standards in the packaging of products in flowpacks. For the first time ever, the Flowmodul enables the seamless integration of packaging processes for an extensive variety of products such as confectionery, cosmetics and pharmaceuticals and other flowpack products within its proven top-loading packaging lines. The eighth system component in the packaging machine manufacturer’s portfolio can easily take on small batches, short product lifecycles and high product diversity more efficiently than ever before.

    Innovative strength

    Based on mutual trust and a high level of dedication on the part of its employees, the company has successfully developed a very strong culture of innovation. The company regularly introduces major leaps in innovation, offering all-new dimensions of customer value and conquering new market sectors with its state-of-the-art technologies. Schubert’s objective is to provide customers with future-proof automation solutions that are easy to use, flexible in format conversion and extremely powerful and stable in function.

    Well-known brands from diverse industries, such as Ferrero, Nestlé, Unilever and Roche, rely on Schubert’s automation solutions, as do many small, medium-sized and family-run businesses. With its subsidiary company, Schubert Packaging Systems, the Schubert Group combines machine design with extensive expertise in systems design and engineering.

    Schubert is a family-run business – with Gerhard Schubert, the company founder, and his son Ralf Schubert as Managing Director, running the business together with Peter Gabriel, Head of Administration, and Marcel Kiessling, Head of Sales and Service. The third generation is also represented within the company, with Johannes Schubert, Gerhard Schubert’s grandson currently acting as Product Manager. In addition to international locations in the United Kingdom and North America, the Schubert Group has subsidiaries in the fields of IT, precision parts and packaging services. Today, the company employs 1,250 people.

      The Schubert success story

    The Schubert success story began in the 1960s with the controversial idea to build a packaging machine using standard components from which, depending on the task, exactly the right line would be assembled. To implement his idea, Gerhard Schubert founded Gerhard Schubert GmbH in 1966 and began construction of the first carton erecting and gluing machine (SKA), with which the Weiss company in Nuremberg packaged its world-famous “Lebkuchen” gingerbread.

    Over the course of the next years, the entrepreneur developed the first SSB modular machine (Schubert-Sondermaschinen-Baukasten) for filling and sealing cartons via top loading – whereby the line could be assembled from various mechanical modules depending on the task at hand.

    Using the human body as model – robots in operation

    In the 1970s, Gerhard Schubert was already considering how he could use robotics to maximize the flexibility and adaptability of packaging operations. The basic idea behind his vision was quite simple: human nature would serve as the perfect model for his packaging machines. “At some point, I asked myself what was the most flexible, adaptable development that nature had ever created? The answer was the human being,” says Gerhard Schubert. “With this in mind, my vision was to develop a machine built following human principles: simple mechanics, a high level of intelligence and the use of tools. This was the platform upon which we built our machines.”

    In 1981, Schubert presented the first ground-breaking result of these considerations at the Interpack fair: ROBY, the first-ever packaging robot. This four-axle robot picked up and placed individual products, such as chocolates, from a feeder belt into a box or plastic tray. Schubert achieved a major breakthrough with the development of the two-axle SNC-F2 robot which was first used in 1985. Equipped with the right tool, it became possible with this robotic unit to perform a variety of packaging tasks, such as erecting, filling and closing boxes. This represented an important step towards standardization.

    As early as in 1985, Schubert brought together its technical expertise in optical image processing with experts from the Nuclear Research Center in Karlsruhe, Germany, to set up its own development department. Since then, the company has ranked among the pioneers in this key area as well, and just recently reached a new milestone with its market-ready 3D scanner. Over and above product surfaces, the 3D scanner can detect volume, thereby increasing performance options in the packaging process – for pick & place operation as well as in quality control.

    In 1996, with its F-44 continuously operating picker line, the company launched the first machine with an intelligent control system. The VMS packaging machine control system set the stage for a simple machine structure with a reduced number of mechanical components, which led to the development of today’s modular sub-machines.


 Products

  • Schubert lightline Pickerline
    Pre-configured pick & place packaging machines for standard packaging tasks....

  • The lightline Pickerline is designed to perform key pick & place applications - with all the efficiency and quality you expect from a TLM system from Schubert. Thanks to the preconfigured submachines, the picker line is not only very affordable, you also benefit from short delivery times and fast set-up.

    Variably standardized

    Schubert F4 robots carefully pick up the prodcuts from the conveyor belt and place them in trays. We will design the most suitable robot tool for your product - whether brittle, sticky or fragile. Integrated 3D image recognition systems detect the position, location, height and quality of the products and ensure that the robts only pick up flawless products.

    Flexibly adaptable

    The preconfigured submachines are scalable: if you want to achieve higher performance, you can simply easily extend the number of F4 robots or machine modules. Another benefit: if you want to package the products in flowpacks, the lightline Pickerline can be seamlessly connected to the lightline Flowpacker.

    Facts & Figures

    • Scalable performance through possible addition of preconfigured sub-machines
    • 1,2,4 or 6 F4 pick-and-place robots to meet individual performance requirements
    • Quality assurance due to 3D image recognition systems
    • Individual robot tools, easily exchangeable for new product formats
    • No limitations in performance or flexibility
  • Schubert lightline Flowpacker
    The Flowpacker, which consists of preconfigured sub-machines, packages naked, already packed or trayed products in flowpacks – with all the efficiency and quality you expect from a TLM system from Schubert....

  • The Flowpacker is ideal for packaging different product formats in flowpacks – whether flat or lying on the side, stacked or already pre-packed.

    Due to its design as a preconfigured machine, you benefit from fast delivery and you can use your Flowpacker within a very short time. Integrated 3D image recognition systems detect the position, location, height and quality of the products, and ensure that the robots pick up only flawless products.

    Depending on product characteristics and the desired film, the seamlessly integrated Flowpacker is equipped with one of four sealing technologies. For especially heat-sensitive products, we have developed a new patented sealing technology: first, an ultrasonic sealing system closes the flowpack’s longitudinal seam, then a heat-sealing system with a flying cross sealing unit is used. This flying cross sealing unit adapts to the variable speeds of the upstream F4 robots and therefore ensures high sealing quality with constant sealing times.

    Facts & Figures:

    • Scalable performance through possible addition of preconfigured sub-machines

    • 1, 2, 4 or 6 F4 pick-and-place robots to meet individual performance requirements

    • Quality assurance due to 3D image recognition systems

    • Individual robot tools, easily exchangeable for new product formats

    • No limitations in performance or flexibility

    • 4 sealing technologies to choose from:

    • Cold sealing

    • Combination for optional cold sealing and heat sealing

    • Ultrasonic sealing of the longitudinal seam and rotary cross sealing (heat sealing)

    • Ultrasonic sealing of the longitudinal seam and flying cross sealing (heat sealing), ideally suited for heat-sensitive products

    • Handling of different product formats possible: flat, lying on the side, stacked or pre-packed

    • Products can be stacked in any variant

  • Schubert lightline Cartonpacker
    A pre-configured case packer for erecting, filling and closing cartons, with short delivery times, ideal for packaging tasks with a limited number of packaging formats.
    ...

  • Schubert developed the lightline Cartonpacker for erecting, filling and closing cartons. It is an attractive and compact packaging machine that is designed for specific product and packaging formats.

    The preconfigured Cartonpacker is available in four versions for four different types of cartons: trays, trays with lids, RSC cartons or wrap-around cartons. Each Cartonpacker is designed for one product, for example, bags, boxes, bottles or cans.

    Depending on the carton type, the Cartonpacker is equipped with a suitable erecting, filling and closing tool. Schubert offers flexibility within the machine variant: each product type can be packed in different format variants.

    Immediately ready for use

    We deliver the preconfigured machine to you as a unit: you benefit from fast delivery and your Cartonpacker is ready for use within a very short time – so you can quickly expand your production capacity as required and respond to new orders.

    Facts & Figures

    • Available in 4 variants: for trays, trays with lids, wrap-around cartons and RSC cartons
    • Each Cartonpacker is designed for one product: e.g. bags, boxes, bottles or cans
    • Performance: up to 25 two-piece cartons per minute
    • Dimensions: 3.5 x 2.5 metres
    • 3 F2 robots in use
    • One module, compact design

  • New heat-sealing robot in the Flowmodul
    The new cross-sealing unit guarantees consistent sealing times and, for the first time ever, makes it possible to dispense with cold-sealing film, even with heat-sensitive products such as chocolate....

  • The new technology makes it possible to program sealing to the millisecond and ensures constant sealing times. This is because, for each flowpack, the cross-sealing unit immediately adapts to the variable speed of our upstream pick & place robots. Like all of Schubert’s sealing technologies, the flying cross-sealing unit can be integrated into every Flowmodul and combined with other sealing technologies. 

    Facts and figures

    • There are 36 Flowmodul units in use, of which four feature flying cross-sealing technology and eight have ultrasonic sealing technology. Three more have been ordered.
    • They are used to package biscuits, chocolate, marzipan, pancakes and French toast, as well as BFS products from the pharmaceutical industry and many other products.
    • The output is up to 500 packs per minute with a maximum chain speed of 60 metres per minute.
  • Flexible & modular — Schubert’s modular principle
    The particular advantage of Schubert’s packaging machines lies in the modular system design and the ability to individually determine their scope of performance and tailor it to the customer’s needs....

  • Eight standardized system components are combined into a robot-supported packaging system in accordance with the modular principle. The components of our packaging machines are dvidied into three groups: System Components, Sub-Machines and Tools.

    Visit our website for further detailed information: https://www.schubert.group/en/technology/overview.html

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