- Overcoming labor shortage and cost pressure with scalable packaging automation.
- Longer shelf life for bakery with new Amplified Heat Sealing (AHS) technology.
- Gentle handling and stacking of fragile products ensures consistent, high-quality results.
New Richmond (WI), August 7, 2025. Labor shortages, rising material and energy costs, and the growing demand for sustainable packaging are reshaping the bakery industry. At IBIE 2025 (International Baking Industry Exposition), taking place September 14–17 in Las Vegas, Syntegon will demonstrate how its scalable packaging automation solutions help manufacturers meet these challenges while improving efficiency and product quality. As a trusted lifecycle partner, Syntegon supports customers from consultation and planning to seamless integration, reliable operation, and continuous adaptation – backed by deep industry expertise, a broad portfolio, and a global network of service hubs. Whether bakery manufacturers are just starting their automation journey or expanding to fully integrated high-speed lines, Syntegon offers the flexibility, reliability, and innovation they need to succeed. At booth #2165, visitors can explore a comprehensive range of scalable solutions, including new innovative sealing technology, gentle product handling systems, and cost-efficient entry-level equipment designed to help bakery manufacturers automate at their own pace.
Baked goods: tight packages and high automation levels
A highlight at IBIE will be live demonstrations of Syntegon’s innovative packaging solution for baked goods such as brownies. Significantly reducing manual intervention, this system addresses the pressing issues of labor shortage and the need for constant high quality. At the heart of the solution is Syntegon’s HCM high-speed flow wrapping machine. It is equipped with the new, innovative Amplified Heat Sealing (AHS) technology. Compared to conventional rotary heat-sealing AHS delivers exceptionally tight seals by combining rotational and additional linear sealing movements. AHS ensures consistent sealing quality under varying process speeds, even for sustainable mono-materials. In addition, new digital features such as Syntegon’s ‘Guide-by-Light’ status lighting system, Logbook and 3D Error View enhance the user experience for reduced downtime and maximum productivity. Manufacturers seeking a turnkey solution can scale this line with Syntegon’s portfolio of topload and sideload cartoners, along with RSC, wraparound, tray and hood-style case packers.
Toaster pastry packaging system ensuring high product quality
Syntegon will also present a system optimized for gentle handling of delicate toaster pastries. Using the Stacking FIT linear motor infeed, products are gently stacked moments before flow wrapping to minimize breakage and waste. The reliable Pack 202 mid-speed flow wrapper securely wraps toaster pastry stacks in convenient perforated two-piece packs. For a full automation turnkey solution customers may add the intelligent Kliklok MagTRAC collation module grouping the flow packs into layers or side-by-side to prepare for efficient endload cartoning by the Kliklok BEC. In order to complete the line manufacturers may opt for one of Syntegon’s Elematic case packers.
Turnkey packaging system including gentle stacking, flow wrapping, collating, endload cartoning and case packing.
Accessible automation for small and mid-size bakery manufacturers
For bakeries moving from manual to semi-automated operations, Syntegon introduces a cost-effective entry point with the Pack 103 flow wrapper and the Doboy CBS-D 750 band sealer. Designed for a variety of products, these compact machines combine robust performance and flexibility - making them a good choice for growing businesses. The Pack 103 flow wrapper features a hygienic design, quick format changes, and seamless integration. The Doboy CBS-D 750 band sealer delivers high-integrity seals for heat-sealable bag materials. Offering sealing speeds of up to 25 meters per minute, digital temperature control and easy maintenance features like tool-free band changes, the CBS-D 750 ensures reliable performance.
With Pack 103, Syntegon showcases at IBIE an entry-level flow-wrapper, ideal for businesses taking their first steps into automation.
Whether packaging brownies, toaster pastries, cookies, tortillas, or other baked goods, Syntegon supports manufacturers across the entire lifecycle—from consultation and system design to integration, service, and digital performance optimization. Comprehensive Service Agreements maximize value and minimize production risk, while cloud-based solutions such as Synexio offer real-time insights to maximize OEE and sustainability. “With our holistic approach, we don’t just supply machines - we deliver tailored solutions and ongoing support to help customers grow and adapt,” says Brad Baker, Senior Sales Director, North America.
Discover how Syntegon helps manufacturers scale intelligently, reduce operational complexity, and stay competitive — live at booth #2165 at IBIE 2025.
