Orics Manufacturer is a leader in Engineering and fabricating automated filling and sealing machines
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Home cooking pasta is an enduring tradition all over the world, according to market intelligence , pasta is also the most popular meal choice in restaurants. The increasing appeal and take-up of Mediterranean cuisine among global consumers has caused an explosion in the export of pasta, especially spaghetti, which is a type of long, thin and cylindrical pasta. Spaghetti is considered as a healthy alternative to fatty meal-time choices. The convenience of cooking a pasta dish – which takes just a few minutes – has also made it one among the go-to meal options for busy families.
Annual world production of pasta stands at more than 12 million tonnes. EU countries dominate production, with dried pasta accounting for almost 95 per cent of the total domestic pasta production in some EU nations. The quality and choice of pasta products produced in EU is hard to surpass, and ORICS Spaghetti meal packaging machine or tray filling and sealing machine is an example of this validation that has seen European countries top the list of spaghetti packaging machine purchasing for tray filling and sealing– in all shapes and forms – to global consumers.
A ‘typical target’ weight per pack might be 100 grams of a product. The product is fed to the top of the multihead weigher where it is dispersed to the pool hoppers. Each pool hopper drops the product into a weigh hopper beneath it as soon as the weigh hopper becomes empty.
The Multihead scale weigher’s computer determines the weight of product in each individual weigh hopper and identifies which combination contains the weight closest to the target weight of 100g. The multihead scale weigher opens all the hoppers of this combination and the product falls, via a discharge chute, into a tray or, alternatively, into a distribution system which places the product, for example, into cups, Tubs or bags.
Dispersion is normally by gravity, vibration or centrifugal force, while feeding can be driven by vibration, gravity, belts, or screw systems.
An extra layer of hoppers (‘booster hoppers’) can be added to store product which has been weighed in the weigh hoppers but not used in a weighment, thus increasing the number of suitable combinations available to the computer and so increasing speed and accuracy.
Products containing up to eight components can be mixed on a multihead weigher, very accurately at high speeds. The weigher is divided into sections, each with its own infeed. For example, a breakfast cereal containing hazelnuts and dried fruit plus two relatively cheap ingredients, could be weighed on a multihead with say eight heads devoted to each of the more expensive components and four heads to each of the other two. This would ensure high weighing speed while ensuring that overfilling of the expensive ingredients was negligible.
Placing into trays:
A well-engineered distribution system enables you to combine the speed and accuracy of multihead weighing with precise, splash-free delivery of product into trays.
Multihead weighers were used initially for weighing certain vegetables. Their use expanded exponentially in the 1970s and 1980s when they were applied to the rapid weighing of snacks and confectionery into bags. What cherry tomatoes and crisps had in common was that they flowed easily through the machine and into the pack, with no more encouragement than gravity and a moderate level of vibration of the feeders. Since then, the accuracy and relative speed have been extended to many products which would in the early days of the technology have been seen as difficult to handle.
Hyde and Hyde is a food processor and distributor based in Cincinnati, Ohio and Corona, California with a packaging facility offering custom packing services as well as packaging its own-label products for supply to the food services market. The company specialises in the production of trays and bags of mixed salad components for the US market.
In August 2008 the company upgraded its salad packing line with the installation of a new modified atmosphere packaging (MAP) system, which was also able to increase the speed of the line and improve efficiency and accuracy to speeds of up to 60 trays a minute. The system was a MAP fill-and-seal machine designed to produce trays of ready-to-eat salad meals for a fresh produce supplier creating tray based salad meals.
The Model PB-1000 servo-driven, 4-wide, modified-atmosphere packaging (MAP) machine was supplied by ORICS Industries Inc and has allowed the production of very complex products under modified atmosphere. Salad trays can be complicated, yet a single Model PB-1000 can deposit meat, nuts, grated cheese, dried fruit, croutons and even pots of dressing and condiments into the multi-compartment tray before sealing under modified atmosphere.
The accompaniment trays are then taken to the fresh produce supplier where they are attached to a fresh salad bowl, completing the one-step meal product ready for shipping.
The PB-1000 machine is able to achieve its accuracy and high speeds under modified atmosphere conditions because it makes use of automation technology provided by Festo Corporation. The Festo technology includes CPX manifolds with DeviceNet nodes, DSM-CC rotary actuators with hydraulic shock absorbers, DGPL rodless pneumatic cylinders, VAD vacuum generators and cups, DGO magnetically coupled rodless cylinders and a range of custom produced Festo fittings, such as sensors, height compensators, cylinder mounts and shock absorbers.
The CPX manifolds in conjunction with the Device Net nodes allow the I/O interface on the machine to be far less complex and, along with the CPX controller, allow standalone or integrated control and faster fault diagnosis. The machine makes use of an Allen-Bradley PLC supplied by Rockwell Automation Inc and has a digital, touchscreen HMI.
At the start of a typical operation the trays are stored in four magazines. The first operation is their vacuum-based denesting onto rails, from which the trays are pushed into four lanes through the machine.
There are three consecutive weighing stations, each weighing a single product (each station has a 14-head rotary scale system from Combiscale). Each weigher receives the product from floor hoppers via a conveyor belt to their vibratory hoppers, which then transfer it to one of 14 feed buckets.
The opening of the buckets to the fill chute is controlled by the computer using Festo DSM-CC rotary actuators according to the recipe combination required. A system of buckets again controlled by actuators transfers the food component to each of the four trays in the receiving area, which are then moved to the weighing area for check-weighing and inspection.
The next phase is the incorporation of the carton of salad dressing, which is accomplished by a combination of manual placement and an arm controlled by DGPL rodless cylinders and using a vacuum cup to pick up the container of salad dressing. The filled trays are then moved to the sealer, where they are flushed with an inert gas mixture in an evacuated chamber.
Finally heat-seal film is sealed across the tray top and trimmed by a die around the trays before they are moved to the next stage of the packaging process.
ORICS: M.A.P.’d Salads for Hyde and Hyde
Article Appeared: GatewayPackaging.com. Viewed on February 17, 2014