Packaging made easy! - Traypacker and Placepaker

The Traypacker

The Traypacker takes products at full oven capacity via supply cooling conveyors, guides them into multiple lanes, accumulates and indexes them, place them into groups (slugs) of a predetermined count, and drops them into a tray which is positioned precisely by the system. Speeds up to 300 rows per minute are achieved with this process. Various types of cookies can be processed including wire-cut, rotary molded, enrobed, and sandwiched items.

Infeed Section

A special endless conveyor belt with many features to unscramble, receive the product, places it into lanes, accumulate the product appropriately and synchronize it into the Rotodex Indexing device to be registered and prepared for other functions in the machine. Products can be aligned and spaced as required with easy changeover of custom made parts.

Collating and Dump Sections

This section receives the cookies from the Rotodex and forms groups (slugs) of a predetermined count by a state-of-the-art mechanism with an insertion device in conjunction with the back plate, which continues to move outward pushing the slug into a position ready to drop. At a programable time, the hinges go into an open position, thereby, allowing the products as a unit to drop into the trays below.

Delivery Section

Delivery of the filled trays is presented to the downstream conveyors for further processing. The tray conveyor is a flighted servo driven conveyor used to precisely index trays underneath the drop section of collating dump section. The unfilled trays can be delivered to another flighted conveyor through an automatic denester.

Features

• Tray Cushion Capability– The tray cushion is a servo controlled dampening system used to minimize cookie bounce during the dump cycle. The tray is lifted at a certain time and speed just prior to receiving the cookie slug at dump. The cushion lift height is adjustable from the HMI.
• Scalability on Conveyors - Allows ancillary product and tray conveyors to be enabled or disabled. The system allows the user to start the conveyor, monitor the belt speed, and control the belt pitch of each conveyor.

• Flexibility – Our system is adaptable for products with different sizes and diameters. Any style and size of cookie you can think of, including wire cut, die cut, rotary molded, enrobed, sandwiched items, and much more!
• Simple Process- Provides smooth, high speed and easy-to-care operation.
• Quick Changeover - Easily accomplished with change parts in 20-25 The system has the ability to automatically load a wide variety of additional configurations with change parts.
• Footprint -
• Easy Access- Custom platform utilized for operator access to monitor the in-feed section
• Sanitary Design – Our latest improvements on sanitation offer a sanitary and easy to maintain system the most hygienic operation. Stainless steel, titanium, and anodized aluminum construction. This latest design offers minimized plate to plate contact, non-tube penetration for device mounting and stand-offs for an easy clean/stay clean operation. Other design upgrades include:
  • IP65 washdown capable electronic components
  • No chains – Timing belts used for belt drives
  • Polyolefin belting
• High-Tech Control Systems – Fully integrated operator interface, machine timing and control system package for recipe management, maintenance, diagnostics (SCADA), and servo settings. Pivoting touch screen panel to allow easy operator control access from either side of machine.
• Easy Transfer - The tray and product conveyors are both on a decline angle to create the maximum parameters for efficient transfer of the biscuits into the tray cells.

• Denester Option - The empty trays are automatically denested from a magazine and placed into a flighted transfer conveyor.
• Tray Laning Conveyor – to direct the empty trays from the denester and into the lugged indexing conveyor.
• Servo Controlled Motion - The servo control system insures that the timing of the in-feed row of biscuits matches the correct tray position. When the correct tray cell count is obtained, the tray conveyor cycles a new row of empty trays into position.
• Easy Mobility - The system is mobile for effective removal and re-installation and to allow a temporary hand pack system to be installed in-line.

• Auto Reset – device to automatically stop machine in proper place in cycle to start with number one cookie of stack.
• Reject System – to clear machine if jams occur without stopping flow of products.
• Automatic Belt Tracking – for the endless, quick change belt for the infeed section and secondary feed section.
• Automatic Cookie Alignment Device – This device moves the infeed guides to line up with incoming cookie pattern.
• Central Lubrication – Provides automatic lubrication to all lubrication points simultaneously. Multiple zone distribution blocks.
• Servo Gear Ratio Change - Electronically control the in-feed rate to the cell count. Eliminates the need for a gear change part when the cell-count changes.

The Placepacker

The Place Packer takes a full flow of product directly from a continuous cooling tunnel or supply conveyor, orienting individual products, indexing, collating and placing stacks of predetermined counts of products into a plastic or paper tray. Various types of cookies can be processed including wire-cut, rotary molded, enrobed, sandwiched items, and much more.

Infeed Section

A special endless conveyor belt with many features to unscramble, receive the product, places it into lanes, accumulate the product appropriately and synchronize it into the Rotodex Indexing device to be registered and prepared for other functions in the machine. Products can be aligned and spaced as required with easy changeover of custom made parts.

Stacking and Collator Sections

Once the cookies leave the Rotodex indexing device, they are conveyed into the Vacuum pick-up station. This station utilizes a Vacuum manifold bar to pick up complete rows of cookies from the infeed conveyor and delivers them into the collator station. The collator stages cookies in a stack formation per a pre-determined stack count. Once the proper number of cookies is stacked, the collator bottom section is hinged open to dump load cookies into the trays below.

Delivery Section

Delivery of the filled trays is presented to the downstream conveyors for further processing. A special conveyor is provided with cleated conveyor belting. These cleats position the tray in relationship to the collator lane position. This conveyor is Servo controlled and positioned underneath the collator section. It runs in an intermittent fashion indexing the proper number of trays per each machine cycle. The unfilled trays can be delivered to another flighted conveyor through an automatic denester.

Features

• Tray Cushion Capability– The tray cushion is a servo controlled dampening system used to minimize cookie bounce during the dump cycle. The tray is lifted at a certain time and speed just prior to receiving the cookie slug at dump. The cushion lift height is adjustable from the HMI.
• Scalability on Conveyors - Allows ancillary product and tray conveyors to be enabled or disabled. The system allows the user to start the conveyor, monitor the belt speed, and control the belt pitch of each conveyor.

• Flexibility – Our system is adaptable for products with different sizes and diameters. Any style and size of cookie you can think of, including wire cut, die cut, rotary molded, enrobed, sandwiched items, and much more!
• Simple Process- Provides smooth, high speed and easy-to-care operation.
• Quick Changeover - Easily accomplished with change parts in 20-25 The system has the ability to automatically load a wide variety of additional configurations with change parts.
• Footprint -
• Easy Access- Custom platform utilized for operator access to monitor the in-feed section
• Sanitary Design – Our latest improvements on sanitation offer a sanitary and easy to maintain system the most hygienic operation. Stainless steel, titanium, and anodized aluminum construction. This latest design offers minimized plate to plate contact, non-tube penetration for device mounting and stand-offs for an easy clean/stay clean operation.
• High-Tech Control Systems – Fully integrated operator interface, machine timing and control system package for recipe management, maintenance, diagnostics (SCADA), and servo settings. Pivoting touch screen panel to allow easy operator control access from either side of machine.
• Easy Transfer - The tray and product conveyors are both on a decline angle to create the maximum parameters for efficient transfer of the biscuits into the tray cells.

• Denester Option - The empty trays are automatically denested from a magazine and placed into a flighted transfer conveyor.
• Tray Laning Conveyor – to direct the empty trays from the denester and into the lugged indexing conveyor.
• Servo Controlled Motion - The servo control system insures that the timing of the in-feed row of biscuits matches the correct tray position. When the correct tray cell count is obtained, the tray conveyor cycles a new row of empty trays into position.
• Easy Mobility - The system is mobile for effective removal and re-installation and to allow a temporary hand pack system to be installed in-line.

• Auto Reset – device to automatically stop machine in proper place in cycle to start with number one cookie of stack.
• Reject System – to clear machine if jams occur without stopping flow of products.
• Automatic Belt Tracking – for the endless, quick change belt for the infeed section and secondary feed section.
• Automatic Cookie Alignment Device – This device moves the infeed guides to line up with incoming cookie pattern.
• Central Lubrication – Provides automatic lubrication to all lubrication points simultaneously. Multiple zone distribution blocks.
• Servo Gear Ratio Change - Electronically control the in-feed rate to the cell count. Eliminates the need for a gear change part when the cell-count changes.