filling and closing machines - dosomat · the waldner filling and closing machines are outstanding...
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Hermann WALDNER GmbH & Co. KG
Anton-Waldner-Straße 10 – 16 Tel. +49 (0)7522 986-34888239 Wangen im Allgäu Fax +49 (0)7522 986-419Germany [email protected] www.waldner.de
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Filling and Closing Machines Rotary and Inline Machines
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The WALDNER Group of Companies – A Powerful Trio
Today the WALDNER group of companies consists of the following individual branches:
•HermannWALDNERGmbH&Co.KG
•WALDNERLaboreinrichtungenGmbH&Co.KG
•WALDNERLabor-undSchuleinrichtungenGmbH
The quality of WALDNER has been setting standards – forawholecenturynow.Accordingtoourcustomers’requirementsweintensivelyuseourpotentialsandexceedthelimitsofourbusi-nessfields.Thus,thethreeWALDNERbranchesstandforstability,experienceandcontinuityreferringtotheirsizeandintegrationintothewholegroupofcompanies.
WALDNERDosomat
WALDNERLaboreinrichtungen
GmbH & Co. KG
WALDNER Labor- und Schul-
einrichtungen GmbH
Hermann WALDNER
GmbH & Co. KG
Dosomat Füll- und Verschließmaschinen
Process Systems
Wassertechnik
TheWALDNERfillingandclosingmachinesareoutstandingduetotheiradvancedtechnology,greatflexibility,enormouscapacityandabove-averageefficiency.
Themachinesaredesignedforanoutputrangebetween1.000 and100.000packagesperhour,dependingonthecustomer’srequirements.
TheDOSOMATrotarymachineofthetypes1,2,7,10,12aswellastheDOSOMAT16ASforthesterilefillingofsensitiveproductsareespeciallyappropriateforsmallandmidrangeoutputsandfortheuseofdifferenttypesofpackagesandcontainersizes.Duetotheergonomicquickreleasesystemthechange-overtoanothercuporlidformatcanbeachievedeasilyinafewminutes.
Forlargeroutputrangeswerecommendourhigh-performance inlinemachine,typeDOSOMAT20,whichisalsoavailableas an“AS”versionforthesterilefillingofhighqualityproducts.
AnothermemberoftheDOSOMATfamilyistheUNIMAT,afullyautomaticdosingunit,whichcanbeaccessorisedorfullyintegratedasanadditionalfillingunittoexistingclosingmachines(e.g.cuppingplants).
An overview of the range of machines:
•DOSOMATrotarymachine
•DOSOMAT inline machine
•DOSOMATASforsterilefilling
• End-of-linepackingmachines
InterpacGmbH & Co.
www.interpac.de
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Fullyautomaticcupfillingandclosingmachineforfillingavarietyofdifferentproducts intopre-madecups,whichmaybeofplastics,aluminium,carton,coex,tinorglass.Thefillingrangeextendsfromliquidstohighviscosity,powderyproductsorproducts withparticulates.Alsocosmeticandtechnicalproductsarepackedintopre-madecups.Theclosureofthecupsiseffectedbypre-madealuminiumfoils,snap-on-lidsorby sealingaplasticoraluminiumfilmfromrollstockwithintegratedcuttingunit. TheDOSOMATInlinemachinescoveranoutputrangebetween4.000–100.000packsperhour.
Machine design
Thebasicframeofthemachineisofamodularconstruction.Theframehousesthedrivinggroupsandthegearboxwhichareeasilyaccessible.Allproductleadingpartsaremadeofstainlesssteelorplasticssuitableforfood.
DOSOMAT20–Inline
Dosing systems
•Pistondosingsystems• Inductiveflowmeasuring•Massflowmeasuring•Weighingdosingsystems (e.g.forfruitormeatpieces, powdersetc.)•Pocketfillers(muesli,chunks)•Augerfillers•Roboticsystems/pick-and- placeoftechnicalarticles, etc.
Theappropriatedosingmethodisavailableforanyproduct.
Drive versions
•ServomotorviaELAU PacDrive•Frequency-controlledmotors•Mechanicaldrive•Pneumaticdrive•Orcombinationsofthese features
Thedrivetrainisbyservomotororbyfrecquency-con-trolledmotor-gear-combina-tions.Forthemaindrivethehightestpriorityisgiventosmoothaccelerationanddecelerationforanyproduct.
Closing Systems
•Heatsealing•Specialheatsealingfor aluminiumcups(sterilisable)•Hot-melt(cosmetics)•Snap-on-lidding,withor withouttamper-proofclosure•Ultrasonicsealing• Inductivesealing•Sealingfromrollstockand lid-cutting•Sealingfromrollstockwith integratedlidcutting
DOSOMAT 20.10 AS incl.sterilisationofpackagingmaterial
Capacity:25.000cups/hour Theintegratedcase packeroftheDOSOMAT20inlineassembles,accordingtothepackagingarrangement,thecupsfromtheslatconveyorandplacesthemintothepre-madecartonortray.
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Fully automatic case packer
Theintegratedcasepackertakesthecollationofsinglecupsandstacksthemautomaticallyintothepre-erectedcartons.
This machine is equipped with a sealing from rollstock including print registration
Thesealingfilmisunwound,adjustedbymeansoftheregistrationmarksandsealedtothetray.Inthefurtherprocesslongitudinalandtraverseknivescutoutthesingle-portioncupswithoutleavingresidualmaterial.
DOSOMAT20–Compact
Fields of application are: Dressings
Thismachineisprimarilyusedforfillingdressings,mayon-naiseorsimilarproductsintosingle-portioncups.Capacity:10.000–40.000cups/hour
Thesingle-portioncupsaredestackedintoatraywith24cells,insertedintotheDOSOMATmachine,filledwithproduct,separatedandfinallypackedincartons.
DOSOMAT 20.24 CompactWithintegratedcasepacker
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ThedelicatessenindustrytrustsinWALDNERDOSOMATmachineswhenitcomestothecarefulfillingandpackingofsaladsorsimilarproducts.Inthiscasethefillingrangeextendsfromsingle-portioncupsuptolargebins,whichcanbefilledwithherringsalad,shrimpsalad,beansalad,coleslaw,potatosaladetc.
DOSOMAT20–Delicatessen
Lid magazine/lid setter
Thepre-madeandembossedsealinglidsaretakenfromthemagazineviavacuumsuckersandplacedontothecups.
Thedestackingofthelidsiseffectedbymeansofspecialscrolls,inordertoguaranteeacorrectseparation.Automaticlidscan on missinglid=machinestopsanddisplaysfaultmessage.
Cup feed:
Thecupsetterisloadedfromthelinearbuffermagazine,inastand-aloneversionorintegratedonthemachine,from a cup carousel or from an alternativestoragemagazinespecifiedbythecustomer.
Dependingonthecupmaterialupto1.500cupsperlanecanbestoredinthelinearmaga-zine.Therecupsarefedinstackstothecupsetter.Thesystemassuresanoptimalbuffertimedependantonthemachinespeed.
DOSOMAT 20.6Fillingof1kgcupswithtamper-proofsnap-on-lidsCapacity:16.000cups/hour
Fields of application are: delicatessen
Hygienicdesignandfullflexibilityarethemainrequirementsofthedelicatessenindustry.
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WALDNERDOSOMATmachinesarethemarketleadersintheinnovativefillingandpackingofPaté,meat-spread,liversausageetc.intoplasticcupswithre-closablelids.Engineering,constructionandserviceofthemachinesaregivenspecialattentionbyWALDNER.Duetoperfectqualityassurancesystemscanbetracedbackandhencethehighestqualitylevelbecomesastandardfeature.
DOSOMAT20–Paté,LuncheonMeat
Sealing unit from rollstock
Withintegratedsealing-/cuttingunitforsealingandcuttingthefilmsimultaneously,including rewinding of skeletalwaste.Aservodrivensealingstationisincluded.Aspecialsealingheadmaterialwithsimilar
propertiestothatoftheconductivityofcopperandresilienceofstainlesssteelisusedinordertoachieveminimumtemperaturefluctuationsandabalancedtemperaturelevelpluslonglife.
Theproductisconveyedtothedosingunitbyvacuumfillerincludingcompensationcylinderandfilledintothecupsthroughaprovenpistondosingsystem,whichincludesaspeciallydesignedrotarycutter.
Inordertoobtainaminimumcontentofresidualoxygenitispossibletoequipthemachinewithaclosedchamberforevacuatingthecupheadspaceandforasubsequentflushofprotectivegas.
DOSOMAT 20.5 withsealingfromrollstock,cupevacuationandgasflushingwithresidualoxygencontentof≤0,3%
Thecupsaredestackedfromthemagazinebyamechanicallydrivenscrollsystemwhichguaranteesperfectdestackingwithaminiumoffaults.
Thecupsarestabilisedanddrawnintothecupslatwithvacuumassistance.Automaticcupcheck:onmissingcup,themachinestopsanddisplaysafaultmessage.
Cup setter with control unit
Fields of application are: Paté, Luncheon Meat
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Fields of application are: dairy products
FortheDOSOMAT20ASmachinethecupsandlidsaresterilisedwiththemostadvancedtechnology.Thesubsequentstationsarecovered,hermeticallysealedandflushedwithsterileairsoastoavoidanyrecontaminationofthepackaging.
DOSOMAT20AS–WithSterilisationofPackagingMaterial
Cup sterilisation
ThesterilisingagenthydrogenperoxideH202issprayedthroughspeciallymanufac-turednozzles.Theatomisedcleaningagentismixedwithaflowofhotsterileairandblownintothecupsviadeliverynozzles.Thisprocessensuresgoodsprayingofthecupswithoutformingdrops,whileanoptimalreactivetemperatureisreached.Thecupsaredriedwithhotsterileaironthefollowingmachinestations.
TheairloadedwithH202 is dischargedexternallyandsafelyawayfromthebuild-ing.Allcleaningmediaarecompletelypreparedinaseparatemodule.
Exactcontrolanddosingofallcomponentsguaranteeoptimaldegerminationrates,whilethemachinesurround-ingswillbelargelyfreeofcontaminationthroughthesterilisingagents.
CIP cleaning / SIP sterilisation
Execution:Thisversionincludesaclosedhopperwithsprayballandelectriclevelcontrol.Theentiredosingunitcanbecleanedinplacewithoutdismantling.Toinitiatethecleaniningprocedure,thecircuitisclosedbymeansofanautomaticlockingcleaningadapter.
Allcomponentsandsealsmeettherequirementsforfoodproductsandcanbeadjusted
tothespecificrequirementsatthecustomer'slocation(3A,EHEDG).TheWALDNERstandardwhichappliestoallCIP/SIPrelevantpartsavoidsdeadlegsandotherpointsofcontamination.Thesterilisationprocedureofthedosingunitiscontrolledthroughsafetychecks(timeandtemperature).Thismeansthatthedosingunitisonlyreturnedtoproduction,whencleaningandsterilisationissuccessfullyachieved.
Lid sterilisation
The aluminium film lids are takenfromthelidmagazine,sterilisedwithstrongultravio-letradiationandplacedonthefilledcups.Forthissterili-sationnon-ozonicprojectorsareused.Asophisticatedaerationsystemusingsterileairallowstheuseofevenplasticfilmlidsonthemachine.
Optionally,infraredorH202 systemsareavailableforsterilisation.
ThesubsequentstationsofDOSOMAT20Inlinearecov-ered,hermeticallysealedandflushedwithsterileairsoastoavoidanyrecontaminationofthelids.
DOSOMAT 20 ASforfillingyoghurtinto1kgbucketsCapacity:9.000cups/hour
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TheDOSOMAT1Compactmachineisarobust,easytohandle,fullyautomaticcupfillingandclosingmachinewhichistheidealsolutionforsmallandmediumcapacities.ThebasicversionisbasedontheexecutionoftheprovenDOSOMATmachine,type1.Themechanicalspeedreaches50cycles/minute.However,theactualspeedofthemachinedependsontheproduct,volume,cupsizeandcupheadspace.
DOSOMAT1.1Compact
Thismachineisappropriateforpre-made,stackablecupswithamaximalformatdiameterof125mmforroundcupsand130x90mmincaseofrectan-gularcups.
Theclosurecanbeeffectedbysealinganaluminiumfilmlid,asnap-on-lidorcombinationsoftheselidtypes.
DOSOMATrotarymachinesareadequateforanoutputrangeof2.500–30.000cups/hour.Theyareappropriateforfillingliquids,highviscosityandpowderyproductsorproductswithparticulates.
DOSOMAT1–RotaryMachines
DOSOMAT 1Rotarymachinefor1–4laneswithlaminarairflowcabinet.Capacity:2.500–10.000cups/hour
Quickchange-overtoan-othercupformatisachievedbysimplychangingthecupmagazine.
Anewquick-releasesystemofcupcellswithintherotarytableforasimpletoolessformatchange.Sealingstationwithquick-actionclosurecanbefoldedupwards,againtooless.Appropriatefortwodifferentcupdiameters,exchangeofthesealingplateisnotnecessary.
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DOSOMATmachinesarebasedonthelatesttechnologyandconstantdevelopment.Thequalityofourproducts,anexcellentmanufacturingknow-howandtheflexibilitytomeetthecustomers’requirementsthroughindividualsolutionsarethebasicprinciplesofoursuccess.
DOSOMATRotaryMachines
•Dosingsystemswithout dirttraps•Hose-downexecution•OptimizedCIP/SIPsystems•Laminarairflowcabinetin pharmaceuticalexecution
•Sterilisationofpackaging materialstothelateststate ofart•Energyconduits(forair, power,water)areled throughthecornerpillars
DOSOMAT7
DOSOMAT 7Rotarymachinefor1–6lanesCapacity:2.500–15.000cups/hour
Carriage for format parts
Outstandingfeaturesare:
•Quickchange-overto anothercupsize•Thepossibilitytoruna varietyofdifferentcups•Simpleandelegant operation
•Easycleaning(compli- ancewithHACCP-/EHEDG) throughaself-draining design and a minimum ofmovementsthrough themachinetable.
Simple change of cups through quick-release format parts
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Thefollowingexamplesshowsomeproductsthatcanbefilled:naturalandfruityoghurt,yoghurtwithmuesli,cream,quark,freshcheeseandprocessedcheese;avarietyofsalads,soupandsaucepaste,dressings,mayonnaise,mustard,butter,margarine,spreads,honey,jam,patés,petfood,cosmeticcreams,gels…
DOSOMATRotaryMachines
Dosing systems: •Pistondosingsystems• Inductiveflowmeasuring•Massflowmeter•Weighingdosingsystems (e.g.forfruitormeatpieces, powders,etc.)
•Pocketfillers(muesli,chunks)•Augerfillers•Roboticsystems/pick-and- placeoftechnicalarticles
DOSOMAT10
Theappropriatefillingvalvesareavailableforanyproduct,e.g.aspecialrotarycutterforstringypetfood,ortappetvalvesforveryliquidandthinproducts.
AlmostallfillingunitsareavailableinCIP/SIP.
Available in different variations with:
•Pneumaticdrive•Mechanicaldrive•Servomotor•Frequency-controlledmotors•Orcombinationsofthese features
Sealing from rollstock
DOSOMAT 10Rotarymachinefor2–8laneswithsealingfromrollstockandlaminarairflowcabinetCapacity:5.000–20.000cups/hour
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DOSOMAT12DOSOMATRotaryMachines
Packaging material
WidelydifferingpackagingmaterialscanbehandledbytheDOSOMATmachines:thecupsorlidsmaybeofpaper,plastic,coex,aluminium,tinorglass.
Discharge of closed cups:
Thecupsareliftedoutofthecupcellsandpushedontoabeltconveyorrespectivelytransferredtoasubsequentmachineortoanintegratedend-of-linepackagingunit.
Integrated case packer
ThecasepackerwhichisintegratedintheDOSOMATmachine,takes,accordingtothepackagingarrangements,thecupsoutofthecupcellsandplacesthemintothepre-madecartonortray.
DOSOMAT 12Highperformancemachinefor2–12laneswithlaminarairflowcabinetCapacity:5.000–30.000cups/hour
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TheDOSOMAT16ASmachinesaresuitableforfillingcupsandbucketsandutilisesofanintegratedsystemforsterilisationofthepackagingmaterial.Capacitydependingonmachineversion:3.000–15.000cupsperhour.
DOSOMAT16AS–RotaryMachineWithSterilisationofPackagingMaterial
Requirement profile:
Accuratefeedingsystems,cleanroomtechnology,sterilisationofpackagingmaterial,precisedosingunits,reliableclosingtechnology.
Fields of application:
•Dairyindustry (yoghurt,milk,cream, kefir,quarketc.)•Fruitprocessing (jam,plumandapple purée,etc.)•Foodindustry (mustard,spreads, delicatessen,etc.)•Non-food (pastes,gels,creams)
DOSOMAT16AS–RotaryMachineWithSterilisationofPackagingMaterial
Thelaminarairflowcabinetwiththeprescribedfilterclassescombinedwiththesterilisationofthepackagingmaterialsgiveacleanroomwhichisparti-cularlysuitableforthefollowingapplications:
•Useofpackagingmaterial wherecontaminationmay bepresent
•Useinroomswithair contaminationwhere mouldsandotherbacteria spreadthroughtheair•Useinroomswithlow ceilingandwithahigh aircirculationrate•Useinroomwheretraf- ficpassesthrough(loading trucks,transportofgoods)
Bucket sealing from rollstock Cup sterilisation with H2O2