The multi-level conveyor system enables clean and efficient handling of pressure-sensitive food products from naked primary stage to finished palletized cartons. Designed for extreme brownfield constraints, the solution combines abrasion-free spiral conveyors, format-flexible merges and lifts, and hygienic food-grade construction to minimize footprint while maintaining contamination-free operation. The modular architecture supports near-market production strategies by delivering reliable throughput across primary flow-packing, secondary cartoning, and tertiary palletizing stages.
Establishing local production facilities within existing plants presents manufacturers with the dual challenge of limited space and strict food safety compliance. Complete packaging lines must handle products through multiple stages while meeting FDA guidelines and minimizing disruption to running operations. Products such as pressure-sensitive chocolate bars require careful handling from naked state through flow-packing, secondary cartoning, and final palletizing — all within densely built environments where traditional single-level layouts cannot fit.
This system addresses these constraints by creating a multi-level conveyor backbone that optimizes vertical space and enables seamless product flow between packaging stages. The solution combines hygienic spiral elevation for clean vertical transport with format-flexible modules that adapt to different product and carton sizes. With throughput exceeding 100 pieces per minute and the ability to integrate into running plants through staged installation, the system enables near-market manufacturing strategies that reduce logistics complexity, shorten delivery lead times, and support responsive local production.
Technical Solution
The conveyor system is engineered around the VarioFlow 90 platform, configured for extreme brownfield integration with specialized modules for multi-level routing.
Conveying Platform: VarioFlow 90 provides primary and secondary transport routes at application-dependent speeds of 5–60 m/min. The modular design enables custom curves, merges, and lifts to optimize footprint utilization in constrained spaces. Dual/mattop conveying sections ensure stable product guidance, while adjustable guide rails and modular merges support quick format changeovers without major mechanical rework.
Spiral Elevation: Hygienic spiral conveyors deliver abrasion-free elevation to secondary packaging levels and descent to palletizing areas. The spring-based pressure system and cleanroom-grade bearings prevent dust generation and bearing wear, eliminating contamination risks critical in food applications. This provides demonstrably lower contamination risk than traditional foam-roller concepts—a decisive advantage for food compliance.
Hygienic Design: Food-grade construction following FDA guidelines features stainless-steel contact surfaces, minimal horizontal ledges, and accessible cleaning points. Open frame design with sloped surfaces simplifies manual cleaning and reduces contamination traps.
Brownfield Integration: Staged installation and engineered tie-ins to existing equipment minimize plant downtime during commissioning. Multi-level routing preserves existing machine positions while establishing new production flows with minimal machine rework.
Project Execution: System engineering by Bosch Rexroth, executed in collaboration with local mechanical and electrical partners, ensures coordinated change management and on-site service capability throughout the project.
Key Features & Benefits
Near-Market Production Enabler: Complete packaging line integration establishes local manufacturing, reducing logistics complexity and delivery lead times while enabling responsive market supply strategies.
Validated Food-Grade Hygiene: Abrasion-free spiral concept with spring-based pressure system and cleanroom-grade bearings minimizes contamination risk, supports high quality assurance standards, and meets strict FDA compliance requirements.
Footprint-Efficient Brownfield Integration: Multi-level routing and modular sections fit into constrained areas with limited machine modification, preserving existing equipment investments while minimizing production downtime.
Format Agility and Scalability: Reusable modules including adjustable guide rails, dual/mattop sections, and modular merges support future product and pack changes without major rework, enabling long-term flexibility.
Stable Accumulation and Clean Elevation: Reliable buffering and elevation improves product flow, balances line stations, and contributes to higher overall equipment effectiveness across all packaging stages.
Lower Total Cost of Ownership: In-house spiral technology reduces consumables and maintenance requirements compared with abrasion-prone foam-roller solutions, lowering long-term operational costs.
Build your Application with Bosch Rexroth Products
The solution shown here is based on a system that integrates various Bosch Rexroth components, including conveyor technologies, automation platform, and structural elements. Please note that you can also purchase these components individually from us to build your specific application. The links to the respective product pages are listed here.
Bosch Rexroth VarioFlow Belt Systems: Enable smooth and reliable transport of workpiece carriers up to 20 kg.
The Bosch Rexroth Aluminum Profiles and EcoSafe Protective Fence Components: Are flexible and ensure compliance and safety.
The ctrlX AUTOMATION Platform from Bosch Rexroth: Manages all processes and tasks and is a flexible gateway to other systems.