The BACHMANN GROUP is one of the most remarkable companies Switzerland has to offer in the field of packaging solutions. Virtually every consumer in Germany, Austria, and Switzerland has at some point enjoyed fine chocolate („Schoggi“) wrapped in packaging produced by the BACHMANN GROUP – including the iconic “Toffifee” packaging. However, the company’s product portfolio is much broader and spans from medical technology to flower pot trays for garden centers and DIY stores. But how can a company in high-wage Switzerland produce such mass-market goods profitably and remain internationally competitive? One of many innovative answers is the NX-CAM “Speedform” project implemented with JANUS Engineering AG.
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Founded in 1966, this Swiss family business is divided into three segments: BACHMANN FORMING AG (packaging solutions for food & non-food items), BACHMANN PLANTEC AG (transport and cultivation systems for plants), and BACHMANN DISPLAY AG (displays and POS solutions for retail). Around 280 employees are committed to protecting and presenting products optimally – without creating excessive packaging.
Packaging Quality and Sustainability
Packaging quality plays a crucial role in product shelf life. Since the carbon footprint of the packaged product is usually significantly greater than that of the packaging itself, extending shelf life is key to CO2 reduction. BACHMANN GROUP has already announced its intention to be carbon neutral by 2025. The company keeps an eye on the entire packaging lifecycle in conjunction with the carbon footprint. For instance, a paper-based packaging might appear environmentally friendly but could have a worse CO2 balance than recyclable plastic packaging that can be reused in production. Regardless, BACHMANN constantly researches new materials and packaging types. Numerous innovation awards for sustainable and excellent packaging attest to the company’s creativity and expertise. In 2023, BACHMANN FORMING AG won the “Swiss Packaging Award” with a compostable, stackable plant pot named “Bio-Net” that can be left in the soil after planting.
Highly Automated Production
Anyone who has had the opportunity to visit BACHMANN GROUP’s production facility in Hochdorf, near Lucerne, will recall its high degree of automation. Nearly every thermoforming machine is supported by two or three robots, handling the fast-paced, synchronized production cycles. The machines run 24/7. The packaged products are labeled and conveyed directly into the logistics warehouse via conveyor belts, ready for dispatch across Europe.
Complex Tools
The tools used in thermoforming processes transform plastic film, paper, cardboard, or plastic mesh into practical and elegant packaging. Besides protecting valuable goods, BACHMANN GROUP offers numerous innovations for environmental protection – emphasizing recyclability and resource efficiency. These tools are sophisticated in design and are developed using CAD in the design department. Years ago, BACHMANN adopted Siemens NX as its forward-looking CAD system. Designing appropriate tools for specific forming processes requires significant expertise. Requirements range from appealing designs (like praline trays), functionality (like coffee capsules), to strict hygiene standards (for medical products). Compared to the past, tools have become far more complex – especially due to demands for advanced materials and minimal material usage, posing new challenges for mass production.
In-House Toolmaking
Many tools are produced annually in the in-house tool shop, with several kept in storage at BACHMANN. Maintenance and optimization are also specialties of the toolmaking team, which produces thermoforming tools, cutting tools, and stacking automation systems. Before a new aluminum or steel tool can be milled on a CNC machine, the CAM programming is completed and simulated with generated NC code to ensure smooth operations. This is done at four CAM workstations, all using Siemens NX.
Automation for NX CAM
NX CAM is the specialty of Siemens partner JANUS ENGINEERING AG, based in Sutz, Switzerland. JANUS supports BACHMANN GROUP in all CAM-related matters. The CAM experts identified optimization potential in the interface between CAD design and CAM preparation for CNC machining. Just as automation in production yields savings, model-based automation and standardization in CAD/CAM offer substantial efficiency gains – especially when both areas use the same platform, as is the case with BACHMANN’s 14 Siemens NX workstations.
Promising Analysis
A preliminary analysis by JANUS ENGINEERING AG revealed potential savings of 10–20% in CAD, 20–30% in CAM, and another 20–30% in manufacturing. These gains are made possible through consistent use of NX’s automation and standardization tools. Adjusting work habits is also essential. The success of the new process depends on a collaborative effort between system integrator and users – a process that takes time. Fortunately, JANUS has the experience to guide mid-sized companies through this transformation. Their holistic approach identifies weaknesses and delivers long-term solutions.
Digital Coordination for Optimal Results
Jörg Nussbaum, Head of Innovation at BACHMANN FORMING AG, has been with the company for nearly 20 years and knows the product development process inside out:
“When I started at BACHMANN, 80% of prototype molds were made by hand and only 20% were modeled with CAD. Nowadays, everything is 100% modeled in CAD and CNC-manufactured using CAM. Digitization is fully integrated. Our goal was to digitally synchronize all involved process units to achieve optimum results. With JANUS, we chose the right partner. The savings projected by JANUS are very appealing to us.” Jörg Nussbaum, Designer and Head of Innovation at BACHMANN: “As part of the Speedform project, we achieved the elimination of paper and drawings. All attributes are now included directly in the 3D CAD model.”
Birth of the “Speedform Project”
The project gained strategic importance and full support from executive management. Necessary resources were allocated. Since the main goal was to accelerate tool creation, the project was internally named “Speedform Project” and launched at the end of 2021.
Start in Design
The project started in the design department with the goal of eliminating paper. All tool-related information would be embedded in the CAD model via attributes. Nussbaum explains: “In the past, plans and drawings were printed with notes on tolerances and machining details. For example, a dowel pin was only mentioned in the drawing, not in the 3D model. Through Speedform, we eliminated this by including all relevant attributes in the CAD model. We also defined color codes – for instance, to identify cooling holes instantly. Today, CAM staff receive a complete 3D model with all definitions, making it immediately clear what should be a press fit or where tolerances apply. We also introduced fixed templates for designers to build tools consistently. Before, everyone did it their own way.” These clearly defined structures and MBD (Model-Based Definition) standards improved digital workflow from the outset. For this CAD-specific part, JANUS collaborated with Swiss Siemens NX partner MARENCO AG. Together, they fine-tuned the CAD model for optimized CAM usage.
Goals for CAM and CNC Manufacturing
On the NX-CAM side, JANUS began implementing valuable standards – focusing especially on automation for recurring drilling and milling tasks. The team identified the most frequently used holes and standardized them. Automatic geometry and hole recognition, plus virtual tool library integration, were achieved. Although BACHMANN had already been using a 5-axis milling machine with a pallet changer, its full potential was unlocked only after JANUS optimized the post-processor. Reliable CAM simulation now allows long machining processes to run unattended overnight or during weekends.
CAM Future
The CAM department consists of three employees and two apprentices. The inclusion of apprentices underlines CAM’s central role in securing BACHMANN’s future. At the same time, modern technology and smooth digital processes make it an attractive field for young talent. Jörg Nussbaum is fully satisfied with the Speedform project initiated by JANUS:
“Today, we’re significantly faster and more accurate. Hardly anything is programmed directly at the CNC machine anymore. Even simple plates with a few holes are done through NX-CAM – it’s simply faster and safer. The model-based approach introduced by JANUS is unique. Now, the 3D model doesn’t just know how it looks – it knows how it’s made. A great success! That’s why we’ll continue expanding the Speedform project with JANUS, including standard templates for tools.”