BULKPACK - Full automatic butter filling and packaging plant
Description | Carton erector | Case sealer | Metal detector
BULKPACK – accurate filling and safe packing
The full automatic filling and packaging plant is designed for butter, vegetable oil products and other pasty food stuffs. The solid stainless steel construction assures a long-life cycle even in continuous operation. Progressive safety installations and latest servo-mechanism ensure a smooth operational procedure and product handling.
Safety
- closed stainless steel framework (AISI 304) with safety covers
- integrated safety concept at all accesses
- polycarbonate cover panels for safe monitoring of process
Technology
- direct feed from butter pump – no compensating piston required (no dead ends)
- each station is self-contained, both control wise and electropneumatically, therefore each station may be independently operated
- due to modular design the unit is already complete wired and pretested prior delivery to minimize commissioning time
- motor driven roller foil delivery, thus a smooth constant winding can be guaranteed regardless of the roll diameter, as well as exact foil length
Hygiene
- interior easy to clean
- all parts coming in contact with product are of stainless steel (AISI 316L) or food grade plastic material
- conveyor belt and drive motor optimized for use in typical dairy operation (open, washable, protection level IP 67)
- full automatic CIP-function for all parts in contact with product inclusive filling head from inside and outside
Options
- consistent modular build system – up to 5 modules may be operated in parallel (up to 20 t/h), system can be expanded easily in the future
- filling weights range of 10 to 25 kg possible, change over-time < 10 minutes
- filling modules available with integrated foil delivery or with external bag-in-box-insert machine
BULKPACK – proven, effective in practice and tested
Erected cartons are conveyed to and perfectly filled cartons are released of the system. In-between the filling module takes care of precise dosing and filling of pasty food stuffs.
How does it work?
The conveyor belt carries the erected carton to scale1 on which the tare weight of each single carton is measured before filling. At the following filling position the foil (if fitted with an integrated foil system) is cut and folded around the filling head, the filling head drives with the foil into the carton. The product, e.g. butter is pumped through the filling pipe into the carton.
The filling head is “floating” on the delivered product and in consequence of this lifted upwards to a defined position, supported by adjustable pressurized pneumatic cylinders.
The filling valve is closed and the filling head moves out of the carton. The filled carton is conveyed to scale2 through a free position. The net weight is calculated here (deduction of the tare weight measured previously). The fine dosing then automatically adds the difference to the required weight (set point). A defined quantity of butter is pressed through a small filling pipe into the carton. An electrical heated wire cuts the butter in small pieces. Finally the outlet conveyor belt moves the precisely filled carton out of the unit.
The complete line consists of the carton erector, the filling head and the box sealer. A metal detector after the box sealer can be optionally integrated the line.
Full automatic CIP
A cleaning container is just placed at the filling position to clean the station and the filling head from inside and outside. Feed and CIP-return are connected to the system and all product contact surfaces are full automatically cleaned.
Standard Equipment
- filling module in a rack
- tare scale, gross scale
- fine dosing device
- conveyor belt for feed in of cartons (length 2,000 mm)
- conveyor belt for discharge of cartons (length 2,000 mm)
- CIP equipment for BULKPACK
- electrical control
- pneumatical control
Supplementary Equipment
- foil cut and folding device
- final foil folding and closing device
- additional set-points for different weights
- statistical evaluation
- automatic sampling device
- foil printing
- carton printing
Production data evaluation PDASFILL
The optional available statistical evaluation and reporting program PDASFILL allows to collect the production data in convenient and secure manner. The statistic program runs on a normal PC, integrated within a network. All weight data of each carton is collected and transferred into an Excel sheet. All analysis and diagrams may be adjusted to your requirements. The available option PDASFILL provides a significant contribution to the quality management of your production.
| Technical data | ||
|---|---|---|
| Carton dimensions | 390 x 290 x 100…250 mm (outside dimension L x W x H in mm) | |
| Filling weight | 10 ... 25 kg | |
| Filling accuracy | < +/- 5 g (standard deviation) | |
| Capacity | 4,000 kg/h, per filling head, max. 20 t/h (5 filling heads) at 25 kg filling | |
| Electrical connection | total connected power: | 1kW |
| voltage: | 230 V, 50 Hz, 1 phase, N, PE | |
| min. fuse: | 25 A, cut-off characteristic C | |
| Pneumatical connection | connection: | pipe G 3/4“ |
| consumption: | 330 Nl per carton | |
| pressure: | min. 7 bar | |
| Product connection | DN 125, 5“, Tri-Clamp | |
| CIP connection | feed (max. 2 bar): | DN 50, 2“, Tri-Clamp |
| return: | DN 100, 4“, Tri-Clamp | |
| Measurements and weight | total lenght: | 3,325 mm (each additional module + 2,000 mm) |
| total width: | 2,235 mm (with foil insert 2,780 mm) | |
| total height: | 4,050 mm (filling head erected) | |
| height of conveyor belt: | 700 mm | |
| weight: | 980 kg | |
Carton erector
The ideal feeding station for the BULKPACK line
The feeding module for the BULKPACK line is the automatic carton erector. The cardboard boxes are taken from the magazine (flat packed), rectangular erected and the folded bottom flap is closed with tape and transferred to the filling unit – completely full automatically.
Technology
- electrical system for precise rectangular erection (squaring) of carton
- tape monitoring system
- easy and quick adaptation to different formats
Safety
- closed stainless steel framework (AISI 304) with safety covers
- integrated safety concept at all accesses
- polycarbonate cover panels for safe monitoring of process
| Technical data | ||
|---|---|---|
| Carton dimensions | 390 x 290 x 100…250 mm (outside dimension L x W x H in mm) | |
| Capacity | up to 15 cartons per minute | |
| Cardboard magazine | horizontal integrated magazine, lenght 1,000 mm (optional 1,500 or 2,000 mm) | |
| Transport | side mounted conveyor belts for cardboard transport | |
| Tapesystem | Device suitable for up to 50 mm wide tape and 350 mm diameter rolls. Open tape feed path ensures easy replacement of rolls. | |
| Alarms | tape roll low, out of tape, no adhesion of tape, out of cardboard | |
| Elektrical connection | voltage, min. fuse: | 400 V, 50 Hz, 3 phases, N, PE, 10 A |
| Pneumatical connection | connection: | pipe G 1/4“ |
| consumption, pressure: | 15 Nl per carton, min. 6 bar | |
| Measurements and weight | total lenght: | 2,870 mm |
| total width:: | 1,330 mm | |
| total height: | 1,560 mm | |
| weight: | 990 kg | |
Case sealer
To complete the line: Releasing of boxes
The full automatic case sealer takes over the boxes from the filling module. The machine opens the top flaps, folds the foil, presses the butter surface, closes the carton and seals it with tape.
Hygiene
- interior easy to clean
Technology
- tape monitoring system
- easy and quick adaptation to different formats
Safety
- closed stainless steel framework (AISI 304) with safety covers
- integrated safety concept at all accesses
- polycarbonate cover panels for safe monitoring of the process
- drive motors and conveyor belts in low-wear construction
| Technical data | ||
|---|---|---|
| Carton dimensions | 390 x 290 x 100…250 mm (outside dimension L x W x H in mm) | |
| Capacity | up to 10 or 15 cartons per minute (depending on model) | |
| Transport | side mounted conveyor belts for cardboard transport | |
| Tapesystem | Device suitable for up to 50 mm wide tape and 350 mm diameter rolls. Open tape feed path ensures easy replacement of rolls. | |
| Alarms | Tape roll low, out of tape, no adhesion of tape, out of cardboard | |
| Elektrical connection | voltage, min. fuse: | 400 V, 50 Hz, 3 phases, N, PE, 10 A |
| Pneumatical connection | connection: | pipe G 1/4“ |
| consumption, pressure: | 5 Nl per carton, min. 6 bar | |
| Measurements and weight | total lenght: | 1,900 mm or 2,550 mm |
| total width: | 1,200 mm | |
| total height: | 1,950 mm | |
| weight: | 900 kg or 1,150 kg | |
Metal detector
Catches, what is not part of the foodstuff
The metal detector detects metal-like impurities in foodstuff by means of inductive sensors. All magnetic and non-magnetic particles from the size of 3 mm of stainless steel and 2 mm of ferrous are detected. Identified particles are acoustically signaled and the conveyors belt is stopped.
Technology
- closed stainless steel framework (AISI 304)
- high sensitive detector technique for greater reliability
- integrated control system with individual programmable outputs
- comfortable touch screen with illuminated color display (5,4 inch)
Safety according to HACCP
- regular request for performance test by operator is displayed
- all Data is recorded and stored automatically
Option
Software for PC with following functions:
- network of metal detector with PC
- automated data storage of all production data and report according to HACCP directive
- check of metal detector and display of status (metal detection, number, parameter)
| Technical data | ||
|---|---|---|
| Carton dimensions | 390 x 290 x 100…250 mm (outside dimension L x W x H in mm) | |
| Smallest detectable piece of metal | Stainless steel approx. 3 mm, iron approx. 2 mm, depending on product, moisture and salt content. Please note: cardborad material must be free of metal! | |
| Transport | horizontal conveyor belt for transport of boxes | |
| Product temperature | -20 to +60 °C | |
| Diagnostic | integrated software for diagnostic, automatic self-testing | |
| Elektrical connection | voltage, min. fuse: | 400 V, 50 Hz, 3 phases, N, PE, 10 A |
| Measurements and weight | total lenght: | 1,840 mm |
| total width: | 920 mm | |
| total height: | 1,100 mm | |
| weight: | 250 kg | |