New Never Installed Spouted Pouch Manufacturing Line

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.
      • Design pressure:
        • Tank 47psi at 290°F
        • Jacket 65psi @ 290°F
      • Utility Requirements needed on site:
        • Steam: Clean saturated 3 bar/43.5 psi (g), 143C/ 289°F / capacity 1200 kg/hr 429 gal/hr
        • 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:
    • Cone bottom sweep
    • Sidewall sweep
    • Load cells
    • Bottom discharge
  • Zero back pressure conveyance system

Order of operations: 

1. Lemon Concentrate System
2. Puree Pre-Blend
3. Grain Pre-Blend
4. IQF Puree System
5. Blending Kettle
6. Varo Sterilizer System
7. Waldner Pouch Machine
8. Fenco Pasteurizer 
9. Fenco Cooler
10. Schubert Cartoner/Case Packer
11. Intelligrated Palletizer
12. Lantech Stretch Wrapper