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【3D Printing Applications】What else can 3D printing do? An example of Lonypack leveraging 3D printing to optimize food packaging!

【3D列印應用】 3D列印還能做甚麼？Lonypack利用 3D 列印優化食品包裝的範例！

3DMART |

【3D Printing Application】 What else can 3D printing do? Lonypack's example of optimizing food packaging with 3D printing!

Background of Lonypack Global 

Lonypack Global has 25 years of experience in the sliced cured meat and dairy products sector. Located an hour northwest of Madrid, Spain, the company’s factory boasts a deboning, slicing, and packaging line certified to the highest standards. In early 2022, after consulting with Sicnova, Lonypack decided to adopt 3D technology in their factory, using UltiMaker 3D printers and Kimya 3D printing materials to optimize production processes.


Achieving Greater Self-Sufficiency and Cost Savings

Lonypack began exploring 3D printing in early 2022. Their goal was to develop new component designs to optimize their production processes. Doing so would enable the Spanish company to implement these improvements in their state-of-the-art factory in the most economical and customizable way.

Lonypack Global
Lonypack, headquartered in central Spain, began exploring 3D printing in 2022.
 
Lonypack Global's production plant
They maintain the highest level of certification in their state-of-the-art production plant.


The first challenge was sourcing food-safe manufacturing materials. To improve self-sufficiency and resilience, Lonypack needed a way to regain control over the supply of replacement parts and component manufacturing for its deboning, slicing, and packaging lines.

"3D printing allows us to manufacture parts such as cutting blades, picker combs, turning mechanisms, and sprockets for robotic arms and cutters, with cost reductions of up to 70%." — Román Velasco, Lonypack Industrial Engineering Director 
 
Industrial engineers developed 4 key applications with the help of UltiMaker partner Sicnova and reseller Cosomo 3D
Industrial engineers developed 4 key applications with the help of UltiMaker partner Sicnova and reseller Cosomo 3D.
 
 
Food-safe parts printed with UltiMaker S5

Lonypack began to consider the possibility of using an UltiMaker S5 3D printer to create customized parts for its production line. For this, they followed the advice of Sicnova and its reseller Cosomo 3D, who supported them throughout the technology implementation process.

The UltiMaker S5 is a machine that brings industrial capacity to a desktop size, and its precision and reliability were the reasons Lonypack chose this model. In addition, they opted for Kimya's PETG-S filament, a leading material brand, because its blue color indicates that it is certified for food contact safety.
 
Food-safe parts printed with UltiMaker S5



70% cost savings on parts and reduced lead times

New design solutions were implemented from the outset. Lonypack produced parts including cutting blades, wire picker combs, turning mechanisms, and sprockets, at a cost 70% lower than before.

Lead times were also reduced by 70% compared to previous delivery times.

 
Food safety indicated in blue
3D printed parts save 70% of costs, and the unique blue color indicates food safety. 
 
3D printed robot arm and slicer
A robotic arm equipped with a picker comb lifts fresh meat portions from the slicer onto the packaging.
 
The cutting edge protects the blade during slicing. The picker comb picks up the portions to be packaged. The turning mechanism transports these portions to the empty trays that form part of the packaging. The printer and filament ensure that the printed parts are food-safe throughout the process, thereby saving costs in robotic arm and slicer operations.


Wider Adoption in the Food Industry

Lonypack's initial 3D printing experience was a huge success, as Román Velasco explained: "It's only a matter of time before other food companies incorporate these solutions into their production processes. In the future, they will become important components of factories."



Related Products:
1) Ultimaker 3D Printer Series
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