New 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).
