From 60 Hands to One Machine: The Future of Tray Forming is Here

Delivered a 130% increase in productivity, but also transformed packaging from a production bottleneck into a scalable, strategic advantage.

Overview

Lindt, the iconic Swiss chocolatier known for its premium confections like Lindor truffles and Excellence bars, turned to Pack-Smart Inc. to overcome a critical production challenge. Faced with rising labor costs, inconsistent quality, and capacity limitations, Lindt sought an advanced packaging solution that could dramatically reduce manual labor while increasing precision, reliability, sustainability and output.

Pack-Smart delivered with the TF-3500 Tray Forming and Fulfillment System, a high-speed automation system that reimagines the entire packaging workflow for simplex tray forming.

Download this case study to understand the key capabilities, challenges, solutions, and results Pack-Smart Inc. implemented for Lindt Chocolates.

Spotlight on Impact

The TF-3500 not only delivered a 130% increase in productivity, but also transformed packaging from a production bottleneck into a scalable, strategic advantage. The success of this deployment laid the foundation for a global automation blueprint, enabling Lindt to meet expansion goals with repeatable precision.

Continuing Partnership

Pack-Smart continues to support the client with:

• Continuous performance and capability upgrades
• Remote system diagnostics and uptime optimization
• Integration of sustainable packaging innovations and recyclable materials.
• Retooling for new designs and sizes.

Conclusion

The success of the TF‑3500 deployment at Lindt proves that automation is no longer optional but essential for premium brands balancing growth, sustainability, and uncompromising quality. By replacing a labor‑intensive, error‑prone process with a high‑throughput, data‑driven platform, Lindt more than doubled output, reduced costs, and achieved consistent, audit‑ready quality.

Just as importantly, the modular design positions Lindt to scale globally, adapt to new packaging formats, and continue meeting market demand with precision and confidence — turning packaging from a production hurdle into a long‑term strategic advantage.