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New discharge station DCS for handling of cookies and crackers

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  • Belt slides reduce mechanical stress and minimize product loss due to gentle handling
  • Guard-free design provides optimum process visibility, safe accessibility and easy cleaning
  • Format flexibility for flat and on-edge pile, slug or tray packaging styles
  • Automatic output adjustment of individual legs guarantees higher efficiency thanks to variable product distribution

Waiblingen, June 29, 2022 – Syntegon is launching the Distribution Continuous Slide (DCS), a new highly flexible discharge station for round cookies, crackers and biscuits. The modular discharge system consists of one or more stations arranged one behind the other. These are equipped with belt slides for particularly gentle handling, minimizing mechanical stress and thus reducing product breakage and loss. Providing optimum pack style flexibility, the Syntegon DCS distributes cookies onto belt legs for packing them flat or on-edge into pile, slug or tray packs. Furthermore, the system's guard-free design provides operators with unrestricted process visibility, safe accessibility and easy cleaning.

Belt slides ensure gentle division of product stream

Cookies, biscuits and crackers are taken from the cooling conveyor and are continuously distributed to the leg belts. They are neither pushed nor dropped but slide over the belts and are thereby protected from any mechanical stress. This reduces product loss significantly and leads to efficiency gains, especially when handling particularly sensitive products.

The higher the speed of the belt slide, the more cookies are transfered to downstream leg belts by the DCS. On the individual legs, a further belt slide, arranges the straight product stream into an S-shape. This arrangement ensures the cookies’ and crackers’ are evenly distributed across the entire width of the belt, preventing them from wedging or overlapping. A homogeneous product stream is created, ensuring a constant feed to the packaging machine.

Adjusting performance of leg belts automatically for maximum efficiency

Thanks to its gentle handling, the Syntegon DCS works particularly efficiently and ensures high output and product quality. The system is equipped to handle even briefly fluctuating production volumes intelligently, triggered for example by the failure of a packaging leg.

“Individual discharge stations can run at full speed to avoid production loss”, explains Daniel Bossel, Global Product Manager at Syntegon. “If the product build up on a leg belt becomes too long, the DCS automatically discharges fewer products onto that leg. At the same time, it distributes the surplus to the next stations, automatically increasing their discharge capacity. All legs can continue to operate constantly – until the product storage is empty. In this way, the DCS enables maximum storage times with minimum storage lengths – a significant efficiency advantage.”

Flexibility for varying formats and changing production output

The smart design of the Syntegon DCS also provides high format flexibility: no format parts are installed in the discharge station. For a format change, it is sufficient to modify the belt speeds via the HMI module and save them as a new format. With flat feeders, chicane conveyors arrange the products into columns and feed them to the packaging machine in a constant product stream. With on-edge handling, products are gently transported by vibration to the packaging leg in ZF vibratory channels. The DCS discharge station requires shorter vibratory channel lengths than conventional solutions to achieve the same storage times – another important layout and cost advantage. In addition, manufacturers can add further DCS stations to the discharge system on a modular basis. In this manner, larger production volumes can be handled if the oven capacity is expanded at a later date.

Easy cleaning thanks to vibration-free design

Not only the flexibility of the machine, but also its optimized design confirm the efficiency of the construction. Thanks to the well designed conveyors used within the DCS, additional safety guarding is no longer necessary. Since cleaning requires only a few manual steps, downtimes are reduced. Operators can easily view each process step and reach all machine sections for maintenance purposes.

“Due to the price-sensitive market environment, food manufacturers need to focus on solutions that deliver maximum efficiency gains. Therefore, the Syntegon DCS is designed with a low total cost of ownership in mind”, says Bossel. “Our goal was to develop an innovative and product-friendly system which equips food companies for the challenges of the future. Already we have customers confirm that we have managed to do just that with the DCS discharge station – and a patent for the technology is also pending.”



The discharge system features a modular design and consists of one or more stations arranged one behind the other. It is equipped to handle fluctuating production volumes, triggered for example by the failure of a packaging leg, intelligently.



Providing optimum pack style flexibility, the Syntegon DCS distributes cookies onto belt legs for packing them flat or on-edge into pile, slug or tray packs.


Syntegon_DCS Reinigung_K

Thanks to the well designed conveyors used within the DCS, safety guarding is no longer necessary. This allows for easy and quick cleaning.


Syntegon_DCS Products_k

The discharge station is equipped with belt slides as the products smoothly slide over the belts – this protects from any mechanical stress.

About Syntegon Technology

Processing and packaging for a better life – this is what 5,800 Syntegon employees work for every day. Be it with individual machines, systems, or services, Syntegon helps its customers in the global pharmaceutical and food industries to improve people's lives. The company, which is headquartered in Waiblingen, Germany, looks back on more than 160 years of experience and achieved annual sales of 1.4 billion EUR in 2021. In the pharma sector, the company’s intelligent solutions enable the safe and high-quality production, processing, filling, inspection, and packaging of liquid and solid pharmaceuticals. In the food industry, Syntegon’s flexible and reliable technologies produce and pack confectionery, dry food, frozen food, and dairy products. With 1,100 service experts and a comprehensive service portfolio throughout the entire machine lifecycle from spare parts management to digital line optimization, Syntegon lays the foundation for smooth production processes for all customers. More than 30 sites in almost 20 countries keep a firm eye on Syntegon’s impact on the environment and society. Syntegon is a leader in the development of sustainable packaging solutions, reduces the energy consumption of its machines and pursues ambitious goals to lower its emissions.

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Spokesperson Product Communications Food
Syntegon Technology

Jela Grubesa
Phone: +49 7151 14 2159
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