New Never Installed Spouted Pouch Manufacturing Line
Prepared Food Production Line
Availability:
Available
Location:Paris, TX
Equipment #:E21195
Description:
Complete Spouted Pouch Manufacturing Line:
New never installed complete line from processing to packaging to blend and pump ingredients to an inline filler (all photos taken from FAT documents or are representative photos). The filler opens the pouch, places a spout in the pouch, seals it, fills it, then caps the pouch. The line continues down to a pasteurizer and cooler into a robotic pick and places cartoner/case packer, which leads to a palletizer into a stretch wrapper. Line was designed for filling homogenous, pumpable baby food into aseptic spouted pouches.
Waldner Dosomat 20 inline filler with 10 heads
Premade pouch with spout. Spout inner diameter: 8 mm assembling and welding of spout into the premade pouch done on the DOSOMAT prior to filling
Up 40 cycles per minute/400 pouches per minute depending on the application
10 lanes
Pouch A dimensions:
Width: 84 mm
Height: 109 mm
Gusset Opening: 40 mm
Capacity: 90 grams
Pouch B dimensions:
Width: 84 mm
Height: 120 mm
Gusset Opening: 40 mm
Capacity: 99 grams
Pouch C dimensions:
Width: 84 mm
Height: 140 mm
Gusset Opening: 40 mm
Capacity: 113 grams
Fill capacity: electronically infinitely adjustable, depending on product consistency and head space in the pouch
Hot fill, approximately 90° C
Closure: Screw cap, 1 size, fitting on the spout used.
Pouch magazine: up to 300 pouches per lane
Vacuum pouch denester
Pouch check:
No pouch no fill
No pouch no seal
automatic stop after 5 consecutive missing pouches
Inkjet coder
Barcode scanner
Vision inspection system
Pouch opening: vacuum cups
Pouch Open Check: Performed by inserting a checking cone with sensors into the open pouches. If not open, no filling or sealing will take place
Reject conveyor: Discharges bad pouches or unopened pouches
Spout Infeed: Using a bulk hopper, spouts are fed to the unscrambler.
Spout Unscrambling: Separated and oriented spouts are fed to a 10-lane vertical shaft to be inserted into the pouches
Spout Emptying Function: Extra spouts can be emptied out of the system at a color change
Spout Insert: The spouts are taken out of the vertical drop shaft by a servo-controlled gripper unit and inserted into the pouches. There, at the same time the first sealing of the pouch is executed.
Sealing:
Sealing Station 1: 10 sealing stations weld the spouts to the pouches using hot seal heads with adjustable parameters (temperature, pressure & time)
Sealing Station 2: Similar to SS1 and required to achieve proper sealing
Seal Weld Cooling Station: Water cooled sealing tools ensure quick solidification of the seal between spouts and pouch
Vacuum Leak Test: Rapid vacuum leak (less than 0.8 second) ensures seal integrity. Leaking pouches are rejected
Reject Conveyor: Pouches that are registered as “reject” are discharged from the machine
Filling:
Piston Dosing Filler 1: Fill valves are lowered onto the spouts and seals it off during filling process allowing for proper pouch filling and avoiding potential product contaminations on the exterior of the pouches.
No pouch no fill ensures only open present pouches to be filled. Servo-assisted lowering and lifting the fill valves away
Temperature Sensor: Pouches less than 90° C will be rejected.
Spout Cleaning: Steam nozzles for cleaning outside of spouts
Capping:
Screw Cap Feed & Unscramble: Unscramble, orient and feed 10-lane distribution
Screw Cap Emptying Function: Extra screw caps can be emptied out of the system at a color change
Screw Cap Setter: Pick-&-Place servo assisted set the screw caps onto the filled pouches
Screw Cap Closing: Stepper motors close the caps to adjustable pre-set torque
Camera Inspection: 100% Vision system after screw cap is applied. Will inspect against and illuminated background cap orientation, seal width/height, shoulder width/height, missing or partial date code
Rejection/Sampling: The rejection conveyor manages all “rejected” pouches. It can also be used for sampling a complete line of pouches for QA inspection
Discharge: Pouches are discharged spouts trailing with bar codes facing up
Control unit: suitable for wet room operation. Machine controls and motion control Allen-Bradley, 480 V 3 Ph 60 Hz, 24 Volt Dc Control Voltage, approx. 40 kW connected load. The complete electric / control system is housed in a cabinet IP-65. This is separate from the machine. The control unit is programmed so that all stations are automatically switched on with automatic start and switched off one after another on evacuation.
Programming software: ControlLogix 5000
HMI: PanelView Plus6 15”, Win CE
Servo Controllers: Kinetix 6500
Variable Frequency Drives: Powerflex 40P
Servo Motion: ControlLogix L72
Safety PLC: GuardLogix L62S
Compressed air: FESTO Filter/Regulator, approx. 300 l/min with 6 bar, (10.6 CFM @ 90 PSIG).
Unit is enclosed in safety doors
Schubert carton caser:
Product and Production Rates:
There are three (3) different pouch sizes:
Pouches are laying flat bar code up gusset leading
Four (4) lanes of pouches at 112.5ppm per lane or total 450ppm
Cartoner Rate including surge: 540ppm
Carton Packing: All cartons are wrap-around style cartons, using glue
Packing 4, 6, and 12 count cartons
Case packing (4 count cartons only)
For the 4 count cartons, the pouches are placed oriented standing upright (standing on the gusseted end) at 135 cartons per minute
Pouch A erected carton dimensions:
Length: 133 mm
Width: 62.5 mm
Height: 134.5 mm
Pouch B and C carton case dimensions:
Length: 133 mm
Width: 62.5 mm
Height: 165.5 mm
For the 6 count cartons, the pouches are placed oriented standing upright (standing on the gusseted end) single file into the displable carton at 90 cartons per minute (pouch B and C only):
Erected carton dimensions:
Length: 201.5 mm
Width: 81.5 mm
Height: 169 mm
For the 12 count cartons, the pouches are placed oriented standing upright (standing on the gusseted end) at 45 cartons per minute (pouch B and C only)
Erected carton dimensions:
Length: 225 mm
Width: 110 mm
Height: 171 mm
Case Packing:
The 4 count cartons only need to be packaged into wrap-around cases using glue for closing
6 cartons per case, 23 cases per minute
Pouch A erected case dimensions:
Length: 284 mm
Width: 201 mm
Height: 145 mm
Pouch B and C erected case dimensions:
Length: 284 mm
Width: 201 mm
Height: 176 mm
Transfer unit with magazine
Used to transfer carton blanks, corrugated cardboard to the TLM packaging line
Quick changeover tools for magazines which pivot to assist changeovers
Using a 3-axis robot type TLM-F3
TLM-F44 Robot with vision system
Module consisting of robot arms with drives and vision system
Utilized for picking and placing randomly placed product
4 axis robots controlled by servo motors
Product specific tooling
TLM-F2 Robot
Used for automated positioning transfer and loading of product controlled by servo drives
Programmable via a “teach-in” motion sequence
Format specific tooling for each size/configuration
Use of quick changeover pneumatic clamping with a programmable code to verify correct tooling use
Transmodule
Intelligent system used for complete transport of products and packages
Using an integrated vacuum pump
Move autonomously with speeds up to 4.5 m/s
VMS control system with operator terminal
Decentralized control system
Flash card stores all configuration data.
Electrical supply: 460 V, 60 Hz, 3 phase
NC programming: Standard laptop with Schubert software
Hot melt glue system: NORDSON
(2) IQF Puree Systems
Karl Schnell Emulsifier FL 225 DK Type 187:
Capacity for fine emulsion: up to 7000 kg per hour depending on viscocity and cutting head
Single discharge screw:
Diameter: 360 mm
Thickness of flights: 4 mm
Pitch: 300 mm
All stainless steel construction
Karl Schnell grinders
Soule pre-emulsification handling system
Hydraulic tote dumper:
2000 pound capacity
Insulated hopper with cluster breakers
Screw auger discharge
Weigh belt
Varo sterilizer system
Product:
Baby food, primarily pureed without stabilizer
Process:
4 – 500L Varo/DCI HPT tank skids
12 gpm feed rate to filling line
Vacuum induct into the Varo/DCI process tanks
Pasteurize to 198°F in a Varo/DCI process tank.
Hold for 5 minutes
Cool to 185°F for filling
Transfer to filler via Ampco positive displacement pump
4 VARO HPT Skids for a 12 GPM system
Batch processing (500 liter batches)
Retention of natural and vivid product colors, textures and flavors
Ability to temporarily halt product without product loss
Horizontal cooker with a double jacket for heating and cooling of the product (steam and water)
Temperature: 289° F
Volume of one batch: max. 500Lper minute
Equipped with an agitator, which allows removal of the product from the inner walls of the cooker (PEEK scraper) and allows rapid heating and cooling of the product (coil to be used with steam/ hot and cold water). The speed of rotation of the agitator is adjustable between 6 and 16 rpm.
3.2 bar/46.5 psi over-pressure and vacuum.
Manway cover will include a safety proxy switches.
ASME certified rupture disc with sensor.
Vent assembly for high/ low flow.
Level sensor to indicate tank level contents.
All contact surfaces are stainless steel SA-240 316L and finished to 30Ra
All other is made from stainless steel SA-240 304, except certain components such as gear, bearings, etc
Insulation of vessel: 2 inch fiber glass and covered with 12 gauge 304 stainless steel. End pieces have no insulation.
Cooling water: max 15 C/ 59°F, 30m3/ hour/ 7925 gal /hr
Compressed air: 6 bar/87psi
Sterile air: 2 bar/29psi
Chart recorder panel and Honeywell recorders
Fenco spiral pasteurizer and cooling systems:
Output: Up to 400 pouches per minute, depending on application
Air pasteurizing system with holding:
Pouch position into belt: 4 pieces across (side by side) |□□□□|
Pouch max dimensions: (L) 140 x (W) 84 x (H) 40 mm
Pasteurizer holds filled pouches at 192°F (core temperature) for 5 minutes
Air temperature inside: Up to 220°F
Primary Thermal Fluid: steam at max 6 bar (min 3 bar)
SPIRAL design and technical data:
Belt width: approximately 800 mm
Drum diameter: 4000 mm
Number of drums: 1
Number of tiers: 8
Tier pitch: 150 mm approx.
In feed height: 1900 ±100 mm
Out feed height: 900 ±100 mm
Cabin max height: 10 feet
Air cooling system:
Cooler cools down the pouches to 90°F (core temperature)
Dwell time: 20 minutes (adjustable)
Air cooling temperature: 40°F (adjustable)
Primary Thermal fluid: chilled water between 28°F–32°F
SPIRAL design and technical data:
Belt width: ~800 mm
Drum diameter: 5000 mm
Number of drum: 1
Number of tiers: 24
Tier pitch: 150 mm approx.
In feed height: 3600 ±100 mm
Out feed height: 900 ±100 mm
Cabin max height: 15 feet
Pouch accumulation:
To collect the pouches in case of any stoppages of the secondary packaging, working with logic FIFO (First in First out). Buffer – accumulation capacity: ~ 7 minutes (±10% tolerance depending on the pouch handling conditions) composed of:
Stailess steel frame with sliding guides with low friction coefficient plastic material
Adjustable feet
Plastic flexible belt composed with modular belt type food grade in plastic material. The belt allows for good product support and high air cross-flow
2 POUCH ALIGNERS AND ACCELERATING BELTS
To increase the interspace between the rows due to the high speed of the filler (25-26 m/min) vs the lower speed of the secondary packaging (15-16 m/min). One system is posizioned just after the pouch filler, the second one just before the secondary packaging input. The system is totally automatic and fully equipped of sensors for a perfect pouch handling. Composed of:
Stailess steel frame with sliding guides with low friction coefficient plastic material
Adjustable feet
Plastic flexible belt composed with modular belt type food grade in plastic material.The belt allows for good product support and high air cross-flow.
Systems are designed to be in an insulated room. None of the insulation panels are included in the system.
Intelligrated Systems robotic palletizer Model 952-2
Up to 100 cases per minute depending on application
Minimum Case Size - 6 in L x 6 in W x 3 in H
Maximum Case Size - 22 in L x 16 in W x 12½ in H
Maximum Load Size - 54 in L x 46 in W x 81 in H
Product squarer
Maximum Layer Weight - 400 pounds
Maximum Load Weight - Chain Hoist 3000 pounds
Maximum Stack, Pallet Dispenser - 55 inches high
Pallet magazine capacity: 20 pallets
Electrical Power - 460 VAC, 3 Phase, 60 Hertz
Compressed Air - 4 CFM @ 80 PSI (Add 4 CFM for Sheet Dispenser)
Infeed Belt - 13ft long, heavy duty two-stage infeed belt conveyor with adjustable side guides
Robots - Vertically jointed 4, 5 or 6 axis servo-powered arms with servo-powered side-clamp tooling
Divider and Layer Accumulation Zones - Belt driven live roller conveyor with 1¾in diameter rollers on 2in centers or .6in pitch modular plastic belt conveyor
Spiral elevator brings the product up to the palletizer infeed
Lantech SLA automatic stretch wrapper system:
Output: Up to 50 loads per hour depending on application
Load size:
Length: 36-58 inches
Width: 36-58 inches
Height: 24-75 inches
Approximately 60 feet of of powered roller conveyor
Corner board applicator
Grain and pre-blend system
Frozen puree tanks
Lemon juice concentrate system
(2) 360 gallon insulated blending and holding kettles with agitation:
