At this year’s interpack Multivac will be presenting itself as a supplier of integrated solutions in packaging and processing. The company’s focus on the main exhibition stand (Hall 5, E 23) will include four fully automated packaging lines, as well as concepts for producing sustainable packaging solutions. There will also be solutions on show for the digitalisation of processes and business models.
Solution for fully automatic packing in trays
The heart of this fully automated line is the compact TX 710 traysealer, which is suitable for packing a broad spectrum of food products thanks to its wide range of possible designs. For printing the upper web, the TX 710 is equipped with a DP 225 direct web printer, which has an integrated TTO 30 thermal transfer printer. A multihead weigher from Cabinplant is used for filling the pots. The pots used are made of mono polypropylene and therefore contribute to meeting the current requirements as regards their recycling. The precise and rapid labelling of the pots is carried out by a conveyor belt labeller of the latest generation, the L 320 model. The H 130 handling module is used to load the pots into boxes.
Solution for packing in board trays
Multivac will also be presenting a packaging line for packing in board trays. Here the trays are run on a R 245 thermoforming packaging machine. The R 245 is equipped with an infeed system for the erected board trays. The trays are lined in the forming die with a suitable plastic film, which provides the required barrier for product protection. This film can be separated from the cardboard backing after use, and the individual components of the pack can then be directed to the appropriate recycling loop. The thermoforming packaging machine is equipped with a DP 200 direct web printer for coding the upper web with the individual product data. A visual inspection system provides reliable monitoring of the print.
Automated line for slicing and packing processed products
The high-output S 1600 slicer is equipped with fully automatic central loading and, thanks to its innovative slicing technology, enables a very high slicing speed of up to 1,600 highly accurate slices per minute to be achieved. The SB 625 transfer conveyor ensures that the sliced product is transferred efficiently to the thermoforming packaging machine. The control of the conveyor is integrated into the packaging machine and slicer, which means the best results are achieved throughout the line. The interface is however designed in such a way, that the conveyor can also be easily linked to slicers from other manufacturers. The sliced products are packed on the RX 4.0 thermoforming packaging machine, which sets the benchmark in the market with its sensor system. The packs are precisely labelled by the new CL 2XX cross web labeller.
Fully integrated line for portioning and packing of fresh meat
The heart of the line is the TX 730 traysealer, a new model of the X-line generation. Pre-cut cardboard sheets will be run on the TX 730 for producing MultiFresh vacuum skin packs, and the traysealer will be equipped with an inside cut. Portioning will be performed by the highly flexible and multifunctional GMS 520 singlecut meat portioning machine. Despite its compact construction, TVI’s highly successful model sets the benchmark as regards quality, output, yield, precision, and above all flexibility. The L 310 conveyor belt labeller is used for applying an attractive full wrap label to the MultiFreshTM packs. The I 310 visual inspection system provides reliable monitoring of quality and print even at maximum processing speed.
New TX 810 traysealer
Multivac will be presenting the new TX 810 traysealer to the public for the first time at interpack. Thanks to its two-track design, this model enables a significantly higher output to be achieved.
The company will also be presenting its range of digital services at interpack. Multivac’s groundbreaking solutions provide their customers with a wide range of tools for increasing machine availability and efficiency.
Sustainable packaging solutions
Another focus of the company’s presence at the trade fair is its presentation of sustainable packaging solutions. On display will be a wide range of concepts, which contribute to reducing packaging material consumption in the production of packs, as well as other concepts for producing packs, which meet current requirements for recyclability. One example of this is the Multivac PaperBoard range, which is made up of a wide variety of paper fibre-based materials for producing MAP and vacuum skin packs on thermoforming packaging machines and traysealers.
Resource-saving and flexible filling of sensitive products
The market for sensitive beverages is flourishing. Throughout the world manufacturers of dairy products have recognized the potential of wholesome beverages and expanded their product portfolio over the past few years. Most of the new products are filled into PET bottles. With its new linear InnoPET BloFill ABF aseptic block KHS is satisfying the requirements of the dairy industry for flexible filling technology for sensitive products. Fast format changeovers and a modular design are the ideal solution to the rapid changes in demand producers are now faced with.
Sensitive beverages are becoming increasingly popular all over the world. The demand for functional foods with less sugar in particular is growing. “Keeping to a healthy diet is playing a central role in the lives of more and more consumers,” explains Thomas Redeker, sales director for Dairy Europe at the KHS Group. “The demand for products that are sustainably packaged and attractively presented has also greatly increased in the last few years.”
PET bottles are the ideal vehicles for this new trend. An increasing number of makers of dairy products are thus relying on containers made of polyethylene terephthalate. “Not only producers but also consumers are convinced by their many different advantages,” says Redeker. In particular this includes the great capacity for individual design this type of container has. “PET bottles lend themselves to exclusive design. The cap and label can also be perfectly tailored to the brand. This had a positive effect on the brand positioning at the point of sale,” Redeker states.
The plastic containers also score when it comes to their environmental balance as they are fully recyclable. PET bottles not only provide reliable product protection; they also have good pouring properties.
KHS first recognized the potential of PET containers for aseptic filling 25 years ago. Its latest development is the linear InnoPET BloFill ABF aseptic block. This combines the rotary InnoPET Blomax Series V stretch blow molder with the linear Innosept Asbofill ABF 712 aseptic filler.
The block yields many benefits. It not only takes up less space than the individual machines, for instance; the air conveyor is also no longer required. This cuts down on energy consumption. Another advantage is that personnel costs are reduced as only one operator is needed in place of the former two. “By blocking the machinery and including a continuous clock module we also minimize the risk of soiling. This has a positive impact on hygiene and line availability,” smiles Redeker.
Fast format changeovers within the space of up to ten minutes also help to boost system availability. They are performed under aseptic conditions, doing away with the need for any additional cleaning and sterilization. The short changeover times also let producers of sensitive beverages fill a large number of different stock-keeping units (SKUs) in a very short time indeed. The linear aseptic block is designed to fill milk, mixed milk beverages, juice, smoothies and iced tea into PET bottles holding between 250 milliliters and two liters. The equipment outputs up to 12,000 1.0-liter bottles and a maximum of 15,000 0.5-liter bottles per hour.
Bottlers also profit from the modular design of the dry aseptic block which allows the filler to be expanded at any time. Operators can retrofit their block with a chunk filler or additional filling and capping unit, for instance. “The modular design gives our customers greater flexibility. They don’t have to think about precisely which products they want to bottle when purchasing the block,” Redeker says. “KHS enables them to retrofit the required modules on site as soon as they expand their product portfolio.” This in turn permits beverage producers to react more flexibly to changing market demands.
With the integration of the stretch blow molder the aseptic block gains a number of further plus points. One of these is that the heating system in the new Blomax generation consumes up to 40% less energy compared to most standard heating systems thanks to its optimized near infrared heating concept and new Double Gate technology. This is made possible by the near infrared heater centrally installed in the closed reflector tunnel. In the heater the preforms pass the centrally arranged heating units to both the left and right. The preforms are spaced just around 18 millimeters apart instead of the previous approximately 37 millimeters. The Dortmund systems supplier has thus been able to considerably reduce the number of heater boxes used. The air management system for heater box ventilation has also been optimized. “The fan can be set separately for the neck, reflector and lamps. This means that the machine only cools the areas which actually need cooling,” explains Redeker.
When further developing its linear aseptic filler KHS also focused on increased efficiency. The filling machine for sensitive products is available in both a standard aseptic and ESL version. In the KHS process sterilization takes place in several stages. First, the machine disinfects the neck and bottle interior. Here, the inside of the container is sprayed twice with a hydrogen peroxide aerosol (H2O2) at a speed of up to 80 kilometers an hour. “This ensures that every part of the bottle is sprayed and sterilized; we even achieve this with individual designs and critical shapes,” Redeker states. Secondly, two aerosol reaction cycles are initiated. The process ends with a four-stage drying process which uses sterile hot air.
In order to ensure the quality of the products, it is essential that the aseptic zone is absolutely clean. KHS ensures this by gentle non-contact filling, among other things, performed in two stages. This prevents any excessive beverage foaming.
After filling the bottle is conveyed to the capping unit. Here, the closure is sterilized in the same manner as the bottle in the filling section. This entails two-step disinfection with H2O2 and two drying stages with hot sterile air. “In the capper unit we’ve also made sure that all parts in the aseptic zone have a flat surface. By doing so we can prevent any air turbulence, making cleaning and disinfection easier,” Redeker comments. The bottle is then dated for full documentation of all information. “Our customers can always see which product was filled when on which valve,” explains Redeker.
With its new dry aseptic block KHS has reacted to the current dairy demand for flexible, resource-saving filling of sensitive products. The new system also boosts line availability and considerably reduces energy consumption. Operators also have greater flexibility thanks to the short changeover times: format changes are facilitated by the well-coordinated interfaces. The modular design also enables customers to expand their linear aseptic filler block in order to meet current market demands at all times.
Conveying & Filling, Packaging, Labeling & Storage Measurement, Instrumentation, Control & Automation Plant Construction, Engineering & Components Videos
- bag types: Valve bags of paper, PE or PP-woven
- product type: Powders and fine-grit
- grain sizes: from 30 µ to 5 mm
- industries: Chemical, petrochemical, building material, food
- output: up to 350 bags/h
- most suitable for filling sticky and strongly adhesive products
- fast and efficient product change through saving sort-related machine parameters
- nearly residue-free emptying with innovative chamber discharge
- optimally suited for wet cleaning
Conveying & Filling, Packaging, Labeling & Storage Measurement, Instrumentation, Control & Automation Pharmaceuticals Plant Construction, Engineering & Components Videos
Knowledge that works
Packaging for functional drinks
Health and well-being for discerning buyers: Functional drinks are intended to support consumers in their conscious lifestyle. Manufacturers expect their range of healthy drinks to be packaged in a way that shows the high quality of the products at first glance. TCI from Taiwan also wanted an elegant, sophisticated design for its new product range that conveys value and quality. The drinks must be packed in glass bottles in an absolutely break-proof manner. The solution: flexible TLM technology and special packaging developed jointly by TCI and Schubert.