The Perfect Pull – New VarioFlow plus Chain Conveyor System for Zott

Whether in a gratin or in the irresistible combination with tomato and basil – mozzarella is on the shopping list for many recipes. Consumers rely on the highest standards of hygiene while also being price-conscious. For this reason, quality, cost-effectiveness, and future-proofing were decisive factors for the manufacturer Zott to invest in a new conveyor line for its mozzarella packaging – with the combined expertise of Bosch Rexroth and its Certified Excellence Partner, Heldele.

The Company:
A Century of Dairy Delights

Zott SE & Co. KG, a German gourmet dairy company, headquartered in Mertingen, Bavaria, was founded in 1926. The family-owned company achieved an annual turnover of over €1.2 billion in 2025 with a variety of dairy products, from yogurt creations to diverse cheese types. Approximately 3.5 million kilograms of milk are processed each working day – more than what 75,000 people in Germany consume in an entire year. To keep up with consumer demand, Zott has three production plants and seven sales locations.

The Challenge:
Rising Expectations – Increasing Demands

The requirements in the food industry are constantly increasing. In this competitive and price-sensitive market, maximum hygiene, reliability, and flexibility are essential to meet expectations for production volume and product quality. Systems must be continually renewed or upgraded. Naturally, a key goal is to leverage potential efficiency gains wherever possible. For example, by optimizing cleaning processes, which is faster and easier with the new VarioFlow plus solution.

The Solution:
VarioFlow plus – The Hygienic Chain Conveyor System

After a comprehensive evaluation, the decision-makers at Zott opted for a VarioFlow plus chain conveyor system with stainless steel components from Bosch Rexroth. The decision was supported by clear product advantages such as hygienic design, flexibility, efficiency, and reliability. The long-standing, well-coordinated partnership between Bosch Rexroth and its Certified Excellence Partner – Heldele Mechatronik GmbH, which has a proven track record as a system integrator – was equally convincing. Last but not least, Zott could already draw on positive experiences with Rexroth technology.

The Reasons for Bosch Rexroth:
A Comprehensive Portfolio – Modular and Future-Proof

The decision to use Bosch Rexroth was based on its extensive product portfolio with a proven expertise of working in the food industry, as well as its high level of knowledge in meeting hygiene requirements. Added to this was the modularity and flexibility of the system solution, which allows for future adjustments and expansions without issue. All this, combined with comprehensive support from Bosch Rexroth, created a seamless process from initial planning to maintenance and spare parts supply. Furthermore, with Heldele Mechatronik, an experienced partner was on hand to design and construct the complete side guides of the VarioFlow belt as custom stainless steel add-ons.

The Customer Benefits:
Produce More, More Safely, and More Efficiently

For Zott, the advantages of the solution add up to a complete package.

• Reduced downtime
• Higher production output with the highest quality standards
• Minimized contamination risk

In addition, the reduction in cleaning effort and material losses contributes to lower operating costs. Users benefit from smooth material flow as well as easy system operation and maintenance.

The Strengths of the Solution:
Hygienic, Compact, and Built for Distance

With the new chain conveyor system, Zott reliably meets hygiene requirements. The friction partners—the chain and slide rails—comply with the requirements of FDA CFR 21 and EU 10/2011. Additionally, the ball bearings in the drives, the deflection units, and the curve wheels are made of stainless steel, sealed on both sides, and filled with food-grade NSF-H1 grease.

Thanks to universal drive units that allow for flexible motor mounting positions, the company did not have to make any spatial alterations. Space-saving, patented, low-friction roller curves enable the implementation of lengthy conveyor lines while simultaneously reducing energy consumption.

The Implementation:
Pragmatic, Flexible, and Coordinated

The long-standing partnership between Bosch Rexroth and Heldele paid off during the design and installation of the system. Crucial factors were their deep knowledge of the technology and extensive flexibility – for example, in integrating the stainless-steel side guides. Thanks to this seamless collaboration, the implementation took only a few days and was carried out during a planned production shutdown to minimize disruption to ongoing operations. Only standard connections for power and compressed air were required.

"With our many years of experience and technical know-how, we were able to create a customized transport solution that not only meets the highest hygiene standards but also increases the efficiency and reliability of our customers' production processes."
Gerald Loser, Operations Manager, Heldele Mechatronik GmbH