Sweet Candy Company, located in Salt Lake City—the unofficial “sweet tooth capital” of the United States—has built a reputation for delivering exceptional candy and unparalleled customer service. To keep pace with the rising demand for its flagship product, Chocolate Sticks, the company has introduced an additional production shift utilizing a Schubert Pickerline.
Choose between Dark or Milk chocolate coatings? Indulge in Cherry, Orange, or even Mango flavored jelly fillings? Sweet Candy Company offers an extensive range of chocolate jelly sticks in multiple flavors. Customers have the option to combine up to 10 standard flavors along with a selection of seasonal varieties. The Sweet R&D team is constantly innovating, developing exciting flavors such as coconut-pineapple and mango-chili sticks. Over the years, this signature product has evolved into one of North America’s most beloved sweet confections. Proudly managed by the third, fourth, and fifth generations of the family, this American confectioner has been catering to candy lovers since 1892. With Utah’s historic passion for sugar, Leon Sweet originally relocated from Portland, where he sold licorice root candies from a horse-drawn wagon, to gain better access to sugar mills. Today, Sweet Candy Company stands as the largest national distributor of salt-water taffy, jelly-filled chocolate sticks, sour candies, and chocolate-covered cinnamon bears.
Having navigated various challenges such as pandemics, the Great Depression, and two World Wars, Sweet Candy Company has proven its resilience. “The famous ‘Candy Bomber’ Gail Halvorsen dropped Sweet’s chocolates from his C-54 cargo plane for children in post-war Germany. During Prohibition, the liquor used in flavorings had to be securely stored, with strict accountability,” recounts Rick Kay, President & Owner. He emphasizes, “Whatever it is, folks need their candy. During a pandemic, you may not buy a jet ski, but you’ll likely continue purchasing your orange sticks.” Therefore, it comes as no surprise that throughout the COVID-19 pandemic, Sweet Candy Company operated its facility without any employee furloughs. Notably, demand for chocolate stick products surged, necessitating an increase in production throughput and the addition of another shift.
Transitioning to a Robotics-Based Packaging Line
The previous semi-automated equipment served its purpose well, but it required significant human intervention and managed only about 50% of the upstream product, leaving the rest to be packed by hand. “This equipment was essential in getting us to our current position, but it wasn’t suitable for stepping up our operations,” explains Geoff Dzuida, VP Operations at Sweet Candy Company. “We sought a robotic packaging solution from Schubert to resolve our labor challenges and enhance our throughput.”
As Sweet Candy Company aimed to increase production volume, they recognized the need for a robotic packaging system capable of flexible product counts per box. They prioritized mechanical stability, outstanding customer service, and user-friendly operation. “Schubert became the clear choice for us, and I don’t have any regrets,” affirms Rick.
Innovative Use of Pre-Erected Trays for Quality Chocolate Sticks
The newly implemented Schubert Pickerline packages the premium chocolate sticks into pre-erected trays. An important aspect of this packaging process is the inclusion of a layer of wax paper between two product layers. Equally crucial is the “on the fly” modification of product counts. The bottom layer contains a fixed number of products, while the top layer can be adjusted by ±1 during production. This flexibility is necessary because the product is sold by weight, not by count, and can be managed easily via the machine’s HMI during production.
1920 chocolate sticks transition seamlessly into Sweet’s new packaging system via an 860 mm wide cooling tunnel belt. In this system, products are pre-grouped in layer formations of 15-17 sticks through the use of 16 vision-guided F4-axis scar robots. Pre-erected carton bases advance down a transport chain, after which an F4 robot loads the first pre-grouped layer into the carton trays. Next, another F4 robot positions the wax paper atop the initial layer before loading the second layer. Ultimately, an F4 robot seals the box by placing the pre-erected lid onto the filled carton bottom.
Reflecting on the machine installation experience, Rick fondly recalls the productive time spent at Schubert’s Headquarters in Crailsheim, Germany. “The FAT in Germany was flawless, and the SAT onsite in Salt Lake City was accelerated and impressively conducted. From initial project planning to ongoing operator training in Charlotte, North Carolina, Schubert has consistently exceeded our expectations,” Rick shares.
“Sweet Candy Company presents significant growth potential. Through automation in their packaging processes, the confectioner is now positioned to enhance flexibility and product availability, enabling them to meet the demands of their expanding customer base,” remarks Armin Klotz, Sales Account Manager at Schubert. “The company culture, coupled with the friendliness and openness of the owner-family and management, is exceptional, fostering a welcoming atmosphere for our teams during onsite visits. One cannot help but notice the parallels to Schubert’s own culture—it seems to be a hallmark of family-owned businesses.”
Website: www.schubert.group
