Part of the Rotamec Group

Fruit, Nut & Seed Health Bar Production Line

A Leicester based bakery needed to automate the production of health bars for major high street brands. 


CovElec have been commissioned to design and build an extrusion line with integrated cutter. The system is PLC controlled with feedback on pressures and distance via transducers and encoders to fully automate the process through HMI interface.


The system comprises a variable pitch opposing helix, twin screw auger with integrated pressure transducer providing pressure feedback to the PLC to maintain a setpoint on the drive screws.


The cutter is a clutch-brake device with capability of 4 cycles per second. The blade rotates at 900 rpm triggered by the encoder feedback on the feed rate from the conveyors.


The most challenging aspect of the design was the transfer of the extrusion to the blade without causing blockages and the ability to continue the transfer to the exit conveyor. After several prototype designs, a solution was found and manufacturing is now complete.


The client is looking to integrate the feed direct to a flow wrapper with a capability of producing 7600 bars per hour.

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