filling and sealing machine

Spaghetti Meal Packaging machine

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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.

Multihead Scale Weigher

A ‘typical target’ weight per pack might be 100 grams of a product. The product is fed[4] 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.

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ORICS: M.A.P Salads for Hyde and Hyde

Hyde and Hyde MAP Salad Line

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.

New machines

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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.

Machine operation

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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

ORICS Introduces U.S. Made Form-Fill-Seal

US-made form-fill-seal by ORICS

ORICS Introduces U.S. Made Form-Fill-Seal

The Orics FFS-30 form-fill-seal system is an intermittent-motion, variable-speed sealing system that forms a maximum tray size of 16″ x 12″ and a maximum tray depth of 4″. The system can be combined with modified atmosphere options or can be purchased with full aseptic construction for certain dairy or medical device applications.

The Orics Form-Fill-Seal Machine is consider by Many to be future of all Sealing Technology and the best way to illuminate inventory of cups and tray in your facility.

Original Interview: Packaging World, September 29, 2013

Watch Orics FFS-30 Form Fill Seal Video.

ORICS FFS-30 Horizontal Form-Fill-Seal machine

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Sunflower Kitchens excels with equipment by ORICS

SUNNY SIDE UP

Thriving hummus producer maintains the cutting quality edge with (equipment by ORICS)

[av_dropcap1]M[/av_dropcap1]aking hay while the sun shines is sound, time-tested advice for any small business trying to grow to the proverbial next level. And these are sunny days indeed for the super-friendly folks running the Sunflower Kitchen plant in east-end Toronto—one of a fastgrowing number of Canadian-based producers of the increasingly popular chickpea-based spread called hummus, a core staple of Middle Eastern diet and cuisine for well over a millennia…

As the company’s buy steroids australia sales steadily increased,prompting four relocations to bigger premises in the past seven years, so had its need for more automated, higher-capacity processing, packaging and quality control equipment,according to Jungreis.

“It was our move to automation that ultimately led Sunflower Kitchens to decide exactly what products to make and distribute into the marketplace,” says Jungreis. “With the ability to do automated fills quickly and easily, we were able to determine exactly what products we could make to fill the market needs.”

The bulk of the plant’s hummus production is handled by the linear model PB-1000 filler and lidder from ORICS Industries Inc., which operates by dropping a small plastic tub from above onto the conveying line, filling it with hummus, vacuum sealing it with a layer of plastic film and crowning it with a semi-rigid, pop-top plastic lid before moving it out of the system for case packing.

Other key pieces of packaging machinery at the Sunflower Kitchens plant include an ORICS R20 rotary filler, …and an ORICS model R30 rotary filler for hot-fill applications.

Original Article: Canadian Packaging, July/August 2013

ORICS – Equipment for every application

ORICS and Spartech sealing machine innovation

Spartech-ORICS partnership creates turnkey packaging solution for food brands

ORICS and Spartech sealing machine innovation

A recent collaboration between ORICS, designer and manufacturer of high-speed packaging equipment and Spartech Packaging Technologies, business segment of Spartech Corporation, has resulted in a turnkey solution for food brands seeking a comprehensive single-source option for food packaging.

A new option for food brands in the North American market, the 1-Seal lidding technology is a durable, sustainable, re-sealable packaging solution. The polypropylene label-lid combo serves dual purposes; capping and sealing rigid plastic containers in one step and eliminating the need for foil or film membranes in the sealing process. The 1-Seal lid is heat-tolerant, microwavable, freezer-to-microwave ready and recyclable in streams that collect polypropylene.

The 1-Seal technology was awarded the 2012 SPI International Plastics Design Competition Packaging Award and is featured in Packaging World’s 34 Best Packaging Designs of 2012. Jeffrey Best, Director of Marketing for Spartech Packaging Technologies, believes ORICS’ reputation as an innovator and trusted leader in automated packaging solutions will be an added value to any food brand looking to transition to using 1-Seal technology.

Best stated, “I have worked with ORICS for many years and during this time they have consistently incorporated new packaging technologies and materials into their production capabilities. ORICS is an innovator and has been recognized by the Packaging Machinery Manufacturers Institute (PMMI) for their efforts. When Spartech decided to commercialize the 1-Seal technology, I contacted ORICS because I was sure that they would want to promote this technology within their portfolio of packaging production capabilities.”

Through this partnership, customers can be assured that both equipment and packaging will work in harmony.

ORICS and Spartech sealing machine innovation

Original Article: Packaging World, October 26, 2012

ORICS: Eco-cut Show Daily Review – October 31, 2010

Pack Expo show daily review of ORICS Eco-cut® Tray Sealer.

No film waste is the key to this tray lidding system from ORICS.

2010-Reynolds-OricsCMTS — CMTS with Eco-Cut

Most cup, tub and tray sealing machinery currently available generate an inordinate amount of excess film that needs to be handled, discarded and ultimately recycled at a significant cost in terms of money, labor and energy.

The unique design of the S-30 and CMTS Eco-Cut® systems by ORICS eliminate this film waste and have proven to be a perfect fit for leading processors in the food packaging industry. ORICS’ Eco-Cut® film feeder technology cuts the film in between each container, leaving no wasted film and potentially saving the facility $35,000, or more, per year in material costs alone. Further savings include reduced labor costs and downtime by eliminating the need to handle and discard excess film.

What’s more, Eco-Cut® also lessens a producer’s carbon footprint and environmental impact by virtually eliminating discarded material. By reducing the material cost for the ongoing purchase of lidding material (film), an Eco-Cut® system practically pays for itself; turning environmentally-conscious eco-friendly design into verifiable savings.

Original interview: Packaging World, October 31, 2010

Revisiting Las Vegas: Vistors Purchase ORICS Equipment

Their 2005 visit to Pack Expo Las Vegas yielded big dividends, so these two packaging professionals plan a return to Vegas for another look-see.

By Pat Reynolds, VP Editor, Packaging World

A. Duda & Sons increased productivity by 70%. Kona Joe Coffee boosted production even more dramatically. How? By purchasing new equipment seen at Pack Expo Las Vegas 2005. Needless to say, principals from both firms will return to Las Vegas for this year’s edition of Pack Expo Las Vegas, sponsored, as always, by the Packaging Machinery Manufacturers Institute (www.pmmi.org).

A. Duda & Sons, out of Oviedo, FL, is one of the world’s largest producers of celery products. It also serves both retail and foodservice markets, selling its products under the Dandy brand name. Products in addition to celery include mandarins, red grapefruits, red and white onions, broccoli, and cauliflower.

With operation centers as far-flung as Michigan, South Africa, and Spain, the firm found it increasingly difficult to maintain necessary production speeds while relying on a manual packaging process.

“Having been to Pack Expo on numerous occasions, I knew it would be a good opportunity to investigate ways we could improve efficiency,” says Steve Bocchino, vice president of procurement and packaging at Duda.

After extensive research, Bocchino purchased a linear-motion S-30-DX Heat Seal Machine from [ORICS]. (www.orics.com) to help increase the value of the company’s Dandy Microwaveable Sweet Corn brand. The sweet corn is fully-husked and tray-packed into individual packages that can go right into the microwave. Both three- and four-count packages are available.

Prior to the purchase of the Orics S-30, Duda depended heavily on a smaller table-top steam sealing machine. “Microwavable corn trays were filled by hand and manually steam pressed closed, requiring excess film and increased labor time as well as low productivity,” says Bocchino.

The sleek design of the S-30 proved to be a perfect fit for A. Duda & Sons. Orics customized the system to include an extended frame and registered film slice-cut mechanism to handle the specially vented printed film that adorns the top of each Dandy Microwaveable Sweet Corn pack.

The S-30’s film feeder technology offers additional benefits. Film is cut in between each container, leaving no wasted film and saving the company more than $35,000 a year. The approach also minimizes environmental impact by decreasing the amount of material discarded.

Installation proved to be an easy, hassle-free process. Orics also offered off-site training, which “was invaluable for our employees,” recalls Bocchino. “They were able to learn first hand from trained instructors how to operate the system.”

The S-30 packs two trays per cycle for A. Duda & Sons and has increased productivity by 70%. In addition, by eliminating the manual packing process, the S-30 has also helped free up employees to handle more strategic tasks within the organization.

Original Article: Packaging World, August 9, 2007

ORICS Helps Nestlé Beneful to receive 2007 Pack Expo Selects Award

ORICS Capper helps Nestlé Beneful receive Pack Expo Selects award

The dog food package for Nestlé Beneful Prepared Meals was selected the winner in the inaugural Pack Expo Selects™ program by packaging professionals attending last November’s Pack Expo Intl., which is sponsored by the Packaging Machinery Manufacturers Institute (www.pmmi.org).

The package incorporates barriers for extended shelf stability, withstands the high temperature and pressure of the retort process, and appeals to pet owners. Thermoformed of a proprietary, clear, seven-layer polypropylene/ethylene vinyl alcohol coextrusion, the package has an inner seal to lock out air and other elements to protect nutrients. A full-body, heat-shrink sleeve label includes windows so consumers can view the product inside. A snap-on lid makes it easy for consumers to reseal and refrigerate any leftovers for future use.

The package is used for eight 10-oz varieties that sell for $1.59 each in about 50% of the U.S., primarily in the East, South, and Southwest. Shelf life is one year from the date of production. Once opened, product should be stored in the refrigerator for up to three days.

A PMMI press release noted that supplier/exhibitors contributing to the Beneful package include … ORICS Industries, Inc. (www.orics.com). Nestlé did not comment on suppliers for proprietary reasons.

Originally appeared: Pack Expo, February 9, 2007

Gill’s Onions Utilizes ORICS Equipment

Onions take to thermoforms

For both foodservice and retail channels, Gills Onions is now offering rigid packaging as an alternative to flexible film bags.

By Pat Reynolds, VP Editor, Packaging World

[av_dropcap1]T[/av_dropcap1]he nation’s leading supplier of fresh-cut packaged onions Gills Onions of Oxnard CA has been busy changing its approach to packaging in both its foodservice and its retail offerings. In both cases a rigid package is now being offered as an alternative to packs made of flexible film.

The firm’s first foray into packaging of fresh-cut onions for foodservice accounts came nearly five years ago when a flexible package was introduced for foodservice accounts. While foodservice operators appreciated the convenience of not having to peel and slice their own onions they suggested buy steroids australia paypal a tray might be more convenient. “They seem to prefer the handling characteristics of the tray over the bag” says Steve Gill who with his brother owns the firm. “The sliced onions are easier to remove from a tray.”

So about two years ago a rotary tray-sealing system from ORICS Industries was installed to package 5-lb portions of sliced onions. That system has since been replaced by a new model from Orics the S-30 in-line system. According to Gill the in-line machine occupies less space in the plant than its rotary predecessor. It also utilizes less lidding material because the film’s width is the same as the tray’s. So unlike the rotary system there is no excess lidstock around the perimeter of the tray that has to be trimmed after the tray exits the heat-sealing tool.

Thermoformed of 39-mil polypropylene by ClearPak Co. the foodservice trays for 5-lb portions measure 103¼8” x 121¼2” and are just over 3” deep. Operators fill and weigh the trays by hand along an 18’ long assembly conveyor. The trays are then placed in an indexing conveyor that feeds them into the cavities of the Orics in-line lidding system.

Lidding material from Packaging Products is a two-layer adhesive lamination of 48-ga oriented PP and 1-mil cast PP. It’s microperforated to give it a permeability that allows the proper respiration rate. In other words CO2 given off by the onions is allowed to escape and O2 is allowed to enter at rates that ensure the 16-day shelf life that Gills Onions needs for nationwide distribution.

Foodservice customers who order trays instead of a bag with a zipper reclosure pay a slight premium says sales manager Melia Alamo. “But they’re willing to because the product is so much easier to access and handle” says Alamo. “We still offer the bag but we’re seeing more and more converts to the tray.”

Shelf life on tray-packed sliced onions is 16 days same as for bagged product. The product is shipped from the Oxnard plant to warehouses in Oxnard Salinas or Los Angeles where it’s sold. “It becomes the buyer’s responsibility to get it through the chilled distribution chain” says Alamo.

And on the retail side

Gills Onions’ entry into the retail market is more recent than the launch of its foodservice line. In April of 2002 it began selling 10-oz zippered bags of sliced or diced onions. But in March of this year in response to retailers who thought it would display better a thermoformed PET cup with heat-sealed film lidding and a snap-fit overcap was being released as an alternative. A second ORICS S-30 sealing machine was installed to handle the retail line. It includes a station near the discharge area where snap-fit lids are automatically applied.

Thermoformed PET cups are 4.5” square and 3” deep. They’re supplied by Cool-Pak. The lidding material a 1-mil DuPont Mylar with a heat-seal coating is from Packaging Products. A pressure-sensitive bar-code label is applied to the bottom of each cup by Packaging Products. The firm also applies a brightly decorated p-s label to the side of each container. This label is printed flexo in four colors and is supplied by Label Technology.

For diced onions the cups are filled automatically by a 14-bucket combination scale from Heat and Control. The Orics S-30 cup sealer sits beneath it. For sliced onions cups are filled by hand and then sent through the Orics machine.

The cups run through the S-30 system two-across at 60 cups/min. Sliced onions are filled 8 oz per cup while diced onions—including a diced onion/celery mix—are filled 10 oz per cup. Cups are manually packed six per corrugated tray. Refrigerated shelf life is the same for the retail cups as for the foodservice trays: 16 days. The cups sell for about $1.99.

“We think consumers will like the cup better and we already know that retailers prefer it because it displays and merchandises better than the pouch” says Gill. “We’ll pay a little more for packaging materials but if we sell more product it will be worth it.”

Gill’s Onions Utilizes ORICS Equipment, the S-30

Originally Appeared: Packaging World, April 30, 2005