JBT - Proseal - Projects - 'The Spine of the line'

Proseal Projects

‘ The Spine of the Line’

Proseal UK LTD Adlington Industrial Estate Adlington Cheshire SK10 4NL Tel: 01625 856600 Fax: 01625 856611

e-mail: info@prosealuk.com Web: www.prosealuk.com

Proseal UK Ltd owns the copyright of this drawing which has been supplied in confidence. It therefore must not be usedfor any other purpose than that for which it has been supplied. Furthermore it must not be copied or disclosed (in whole or part) without the written permission of ProsealUK Ltd.

ALL DIMENSIONS IN MM ALL TOLERANCES TO +0.1 MM UNLESS OTHERWISE STATED

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ALL EDGED TO BE CNC PROGRAMMED OR DEBURRED WITH A 0.5MM X 45˚ FILLET

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DATE DRAWN

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PROSEAL PROJECTS BROCHURE 2018

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EDITION 2

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1:70 REVISION

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Proseal Projects - The Spine of the Line At Proseal we think about ‘The Spine of the Line’ being the tray sealer.

The Proseal tray sealer is an intelligent piece of equipment that during product changeover requires film and tooling to be swapped.

For this reason we decided to make the tray sealer the ‘Spine of the Line’ of any production line - it makes perfect sense to centralise the entire line set-up through the Proseal machine’s innovative and intelligent software to avoid unnecessary delays caused by accessing and setting up the other pieces of peripheral equipment in a large production facility.

This means the operator swapping the product can change the whole line set-up for the next run through the push of a button on their Proseal machine screen; the use of the one screen furthermore minimises the chance of delays as everything is done through one channel, optimising production speeds and simplifying changeover for the operator.

This brochure is a selection of case studies where we have demonstrated our integration capabilities.

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FAST FRUIT As with most soft fruit and fresh produce pack houses - speed = freshness. This customer wanted to become the fastest blueberry production line in the world. We needed to integrate seamlessly with their latest generation grading lines and achieve throughput speeds in excess of 240 packs per minute.

A second machine was required to divert flow between the grader and a fully automated twinlane strawberry production line using a custom three tier conveyor system, designed and built by Proseal .

Purpose built three tier conveyor to allow high speed deposit and punnet weighing - sufficient product is delivered to tray sealer - keep speeds up!

Three tier product quality assessment and weigh check conveyor

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Work in progress station - dual sided

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Slip-stream conveyor 1 to 2 lane diverging conveyor with soft touch buffering

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Integrated scales

Proseal GT6eX-Twin The Spine of the Line

GT6ex-Twin

With increased production capacity the GT6ex-Twin is a fully automatic, high-speed, tray sealing system with the ability to take packs up to 400mm wide, long edge leading into the machine.

Capable of 240 atmospheric sealed packs per minute or 192 vacuum/gas packs per minute on a 16 impression tool, the GT6ex-Twin is a high through-put modular, twin-lane, linear, heat-sealing system. Designed to accept randomly spaced trays from any conveyor.

It is ready to be fully integrated with other line equipment such as tray de-nesters, fillers, multi-head weighers and labellers, combining into a stand-alone, user friendly, fully automatic production line.

Multi lane feed conveyor 3

The Spine of the Line

GT6ex-Twin

THE BRIEF

THE DESIGN

2 to 1 converging system

Product delivery conveyors

Waste buckets

Flat belt conveyor

Product delivery conveyor

Automatic blueberry weighing and grading

Work Stations

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Slip-stream conveyor 1 to 2 lane diverging

Flat belt conveyor

Proseal GT6eX-Twin

THE SOLUTION

Work stations to have produce Delivered to them once graded.

Product placed by hand into the punnets and weighed before being placed on the feed conveyor.

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Proseal servo paddle Slipstream conveyor, designed specifically for speed in excess of 240 packs per minute.

Multiple supplying speed zones help smooth the fluctuating nature of the grading supply.

3 GT6ex-Twin ‘The Spine of the Line’ controlling the start/stop of the produce grader, speed zones, soft touch punnet accumulation and Slipstream lane functionality.

4 Downstream links established for metal detect, check weighing operations and punnet removal conveyors. All signal electronically routed to Proseal GT6 with error handling display on its screen.

4

THE BRIEF

Load recipe utilises TCPIIP Ethernet communications to advise each piece of equipment on the next product - no requirement to individually set product data multiple times

Proseal tray de-nester 1

AUTOMATED FILLING, SEALING AND GAS FLUSHING OF MULTI COMPONENT SALAD BOWLS With the increasing cost of labour in most countries, many food manufacturers are looking to automation to help keep the costs of running production down. In this case the customer was producing 5 component, ready-to-eat salad bowls. They wanted minimum human intervention by keeping line setup and changeover times to an absolute minimum so that production speed of 60 trays per minute is maximised throughout the production shift with the incorporation of MAP Gas Flush.

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Downstream integration with top and base label applicator, metal detector and check weigher

Load recipe

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Proseal twin lane OC conveyor 4

Film verification data received from GT5 to ensure correct film is loaded

THE SOLUTION

Sauce deposit zone

OS Line Gas Check

The Spine of the Line GT5e

The GT5e is an extra-large capacity high speed in-line tray sealer with full vacuum facility. It is capable of 112 Gas Flush (MAP) packs per minute on an 8 impression tool.

The GT5e is a high throughout single lane machine designed to run in conjunction with auxiliary equipment such as tray de-nesters, fillers, multi-head weighers and labellers.

At the core of the ‘e’ design is its flexibility to perform any style of heat seal to a pre-formed tray, be that atmospheric, MAP, VMAP, Skin, Skin Plus or Skin Deep.

Each of these options can be added now or at a later date, or indeed removed as necessary. This flexibility provides the user with the assurance that whatever the latest packaging trend might be, they have equipment suitably geared for the future.

GT5e

THE DESIGN

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2 to 1 converging GT5 Spine of the Line stores recipe data for all peripheral pieces of equipment

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Centralise the recipe loading through Proseal GT5e machine - integrate; bowl de-nest with the Proseal OC fill line conveyor system.

2 Trays will arrive under the multi-head weigher, Proseal OC Conveyor signals its arrival and product is dispensed into trays, moving on to the next station and finally to a sauce depositor.

3 The conveyor system will deliver the filled salad bowls, via servo motion, to a Proseal GT5e, high-speed tray sealer.

4 Top layer pre-printed film receives final date coding by an online thermal-transfer printer incorporated with a Proseal film verification vision system, i-film.

5 Once sealed trays travel to downstream interception of trays with top and base label applicator, metal detector and pack weigher.

Trays then crated for shipping to retailer.

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1

THE DESIGN

Tray in tray simultaneous meeting point if the product eliminating the need for human intervention

THE BRIEF

The GT4e machine provides a ‘hub’ of central control All upstream and downstream equipment communicates and is controlled through this system

GT4 in-line tray sealer Fully automated tray de-nesting, filling and sealing

Filled trays are guided into the machine on the infeed conveyor

AUTOMATIC VACUUM GAS, RED MEAT PACKAGING LINE Proseal was approached by a customer to build an automated beef portion and package line sealing 50 packs per minute.

They wanted automation to reduce labour costs and improve efficiency.

The line would need to portion out blocks of pre-minced meat into trays to be sealed in a Proseal tray sealing machine capable of Vacuum Gas Flush (MAP) packaging.

Check weigher and metal detector before packing 4

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The Spine of the Line GT4e

At the centre of this line is the GT4e tray sealing machine capable of sealing up to 84 Vacuum Gas packs per minute. It is an automatic, large-capacity, highspeed tray sealer designer to be flexible allowing the user to perform any kind of heat seal to a preformed tray; be that atmospheric, MAP, VMAP, Skin, Skin Plus or Skin Deep. Each of these options can be added now or at a later date, or indeed removed as necessary. The GT4e is, as standard with all of our GT range, fitted with Proseal QR conveyors - a quick release conveyor system that facilitates rapid infeed conveyor removal when a deep clean is required.

GT4e

Automatic meat depositor uses customizable dies to determine deposit size, shape and weight

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Automatic tray de-nesting system utilizing tray stack conveyor for automatic magazine reloading

THE SOLUTION

De-nest trays move continuously to the tray in fill point

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The meat is portioned in a third party vacuum filler with a forming unit which then deposits a formed ‘brick’ of meat onto a hygienic Proseal flat belt conveyor.

The meat then arrives at a placing system that puts the meat into a waiting tray, which was de-nested off the side of the line and fed in on a separate conveyor.

The filled tray is then transported to the Proseal GT4e tray sealing machine along another hygienic conveyor that is fully integrated into the GT4e control system.

Once in the heat sealing tool the trays are subjected to a vacuum to remove all the residual atmosphere and then flushed with the correct gas mix before it is sealed

5 Sealed trays are transported out of the GT4e on the out-feed conveyor before passing through an end of line check weigher and metal detector - all equipment is centrally controlled through the GT4e.

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HIGH SPEED PRODUCTION LINE FOR MULTI FORMAT READY MEALS To meet the increasing need for faster production, this customer’s aim was to produce multi-component meals at a rate of 120 packs per minute and reduce operator activity by 68%. This would require a high speed production line that would be space efficient enough to fit within the constraints of their existing high care production facility and be robust enough to meet the strict cleanliness standards.

The line would also need to integrate into the customers existing spiral freezer.

THE DESIGN

THE SOLUTION

18 Head weigher deposits Protein

Service/Hygiene integrated platform

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The production line set-up is centralised by holding all recipe data in the GT2sXTwin, which in turn, transmits instructions and data to all peripheral pieces of equipment depending on which product is running.

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The customers existing multi-head weigher installed onto a Proseal twin lane, servo-driven, indexing, OC conveyor.

The OC conveyor is the master control system in synchronising tray de-nesting and filling functions.

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Once filled, the trays are transported to the Proseal GT2sX-Twin machine for top sealing.

They travel on the custom built Proseal 180 degree conveyor, ensuring rapid but controlled transfer for quality and efficiency.

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Sealed trays will pass onto a Proseal switching conveyor. This channels the two lanes from the twin machine into three lanes for spiral freezer loading at the end of the line. Once frozen trays are sleeved for retailer and readied for transport.

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Volumetric sauce depositor Proseal Twin independent drive feed/conveyor buffering

Twin OC conveyor servo-motion incorporating Servo-denest

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Operation Principle Integration of both mechanical and software ensures a smooth ‘no loss’ of product during long production runs GT2sX-Twin Tray Seal Machine The Spine of the Line

GT2sX-Twin

The Spine of the Line

Forming the ‘Spine of the Line’, the GT2sX-Twin is an automatic, large-capacity, twin-lane, high-speed tray sealing system capable of production speeds of up to 150 packs per minute.

Designed to run in conjunction with auxiliary equipment such as tray de-nesters, fillers, multi-head weighers and labellers, combining into a stand-alone, fully-automatic production line. The GT2sX-Twin system is packed with user friendly benefits including our unique QR (quick release) modular conveyor system, this along with the rugged, hygiene conscious , full wash-down safe, construction of the machine makes it ideal for high-care factory environments.

2 lane into 3 lane spiral freezer loader

GT2sX Twin

THE BRIEF

18 head weigher Protein + Veg + Rice + Pasta

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THE BRIEF

SUPER SPEED AND FLEXIBILITY FOR THE GROWING CONVENIENCE MARKET With convenience foods taking up more retailer shelf space than ever, this customer required a high speed ready meal line, capable of producing over 200 packs per minute. Not only did they need speed but the utmost flexibility as this line would have to accommodate 6 different tray types. The customer had pre-existing freezers and space restrictions for us to work around.

All production needed to be fully automated and integrate a range of third party equipment. This included; tray de-nesting for the 6 different tray types, 20 individual automated fill points with check weigh and 2 axis fill on the move.

Once filled, the trays would need to pass onto a product-settling-conveyor, quality-check conveyor and then into a spiral freezer with over a 7000 tray capacity.

Then the filled, frozen trays, would pass into post freeze accumulation and be fed into 2 mirrored Proseal tray sealers capable of 130 packs per minute each – these 2 machines would make it possible to catch up from post freeze accumulation, without stopping the freezer. Finally, the trays would go through automatic cartoning and boxing for retailer.

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Sauce pattern filling station with integrated product scales to use variable sauce fill for correct net weight

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Transfer and filtering into spiral freezing

GT2sX-Twin

Integrated protein weighing depositor

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Integrated rice depositing system

The GT2sX-Twin is a high throughput modular, twin-lane, linear, heat-sealing system. It is designed to run in conjunction with auxiliary equipment such as tray de-nesters, fillers, multi-head weighers and labellers, combining into a stand-alone, fully automatic production line.

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Customers pre-existing spiral freezers integrated into the line

Easy change over tray de-nesters fitted to all 4 lanes

Four lane OC multi-lane conveyor 7

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Integration of 3rd party conveyors feeding two Proseal GT2x Twin sealing machines

Automatic cartoning and boxing ready to ship

Two GT2X Twin machines each sealing 120 packs per minute. A combined output of 240 PPM.

THE SOLUTION 1 The entire line set-up centralised through Proseal software, meaning only the Proseal machine screen would be needed to communicate the recipe data to all peripheral equipment. Automatically setting the correct speed, time and product dispensing.

The Spine of the Line

GT2X Twin

THE DESIGN

4 Lane right angle conveyor geared to ensure all 4 lanes of tray exit at the same time

Transfer conveyor shuffling quid system for product levelling

2 Trays de-nested onto a custom built 4 lane Proseal OC Conveyor.

Proseal de-nest system designed with an easy changeover head-cartridge, to aid quick ‘product change-over’ for the 6 different products run on the line.

3 The customers rice and protein weighing depositors integrated onto the conveyor and into the Proseal machine software sending 11 individual filler control signals to address the 20 different fill points.

4 In-line check weighing system communicates with the sauce filler for variable sauce fill to make net weight.

A 2-axis fill on the move allows for adjustable sauce deposit pattern.

5 A 4 lane right angle Proseal conveyor was designed and built, geared to ensure the trays arrive at filling end point at the same time before heading into the pre-existing spiral freezers.

6 After traveling along the transfer conveyor the filled trays arrive at a custom, Proseal product -settling shaker-conveyor, settling all product in its tray before it travels into the customers’ existing spiral freezer.

7 Once frozen, the trays are split over 2 conveyors from the accumulation area, and to travel to 2 Proseal GT2sXtwin, mirrored twin lane tray sealers, for high speed sealing, at 120 ppm each machine.

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HIGH SPEED SNACK MACHINE This customer wanted to create the best dry fruit and nut packing line possible. The small punnets had to be automatically de-nested, filled from a multi-head weigher or manual hand fill, then heat sealed at a minimum of 80 packs per minute. A seated area for manual product filling was also required on the line.

Collaborate with weigher for guarding integration

Scroll style tray de-nest Can slide off line for service without stopping line

THE SOLUTION

THE DESIGN

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Bespoke conveyor section to allow seated operators to manual sauce fill

Fast rack for hands filling operations Tray sensors for line automation

Working very closely with the customer and their multi-head weigher supplier, we designed a completely custom OC style conveyor, we used a continuous motion conveyor system to achieve the required flow and production throughput. To make the line flexible and future-proofed, we designed ergonomic operator stations for hand filing of product that was not suitable for multi-head weighing and manual application of sauce via filling nozzles designed into the line.

The conveyor system fed a GT2s tray sealer. The GT2s and Proseal OC conveyor were integrated together mechanically, with a continuation of fixed tray guides, to facilitate ultra-smooth transfer of the punnets.

The GT2s film feed system was also developed to allow 8 x prints at full speed per cycle, this is where we developed our first servo driven film feed unit that is now current in all Proseal machines. An anti-static system was also developed into the GT2s film feed to prevent fine nut particles from sticking to the film lid and ensure optimal pack presentation. The outcome of the tight design integrations from all parties and some dedicated control systems commissioning taking advantage of the various servo system across both OC and GT2 - meant the line could achieve in excess of 90 packs per minute in the fully automatic mode.

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Dried product is deposited from the multi-head weigher and the Proseal continuous motion conveyor carries the trays to the next station designed for hand filling.

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Additional product, not suitable for a multi-head weigher, is deposited into the trays by hand.

These filled trays are kept in-line by fixed tray guides on the conveyor.

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The filled tray reaches the Proseal GT2s tray sealer; the film is coded and passes through an anti static system, just before sealing, to provide perfect presentation with traceability.

Bespoke tray guides on infeed

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The Spine of the Line

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Scroll style de-nest system drops empty trays onto the continuous-motion Proseal OC conveyor.

The trays are then carried to the multi-head weigher for filling.

GT2 Tray Sealing Machine controlling the line with 8 impression tool

Travelling head filler integration for continuous motion filling 4

Open conveyor for hygienic wash down

Filling integration control box

GT2s Automatic, large-capacity, high-speed, in-line tray sealing system designed to cut labour costs. It which combines high throughput with rapid tool-changing and space-saving compact design.

GT2s

THE BRIEF

Multi-head weigher

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THE BRIEF

THE DESIGN

AUTOMATED PRAWN PACKING This project was for an automated prawn products line.

The customer required a product distribution system to seal prawns in trays, not always with a heat seal film lid but sometimes with clip-on pre-formed plastic lids.

We designed and supplied three parts; a complete multi-head weigher distribution system with Proseal control system, an OC conveyor with custom guides to suit the various tray types that were being ran. The conveyor system also had a custom vibrating section to level out frozen prawns. The GT1s tray sealer was supplied with 3 heat seal tools and 1 multi pot lid-clipping tool, future integration was designed into the system for lid pick and place.

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Product feed into multi-head weigher

Collaborate with weigher manufacturer to design Proseal control systems and guarding

Product is fed into the weigher which has been fully integrated with Proseal software, control system and Proseal guarding to allow ‘push of a button’ start up of the line.

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Trays are de-nested and travel on the continuous motion Proseal OC conveyor, signalling to the weigher to the multihead weigher, the arrival of a tray to be filled with product.

Filled trays then travel over a Proseal custom-made vibrating conveyor section which levels out frozen product before sealing to ensure consistent seal quality.

Trays arrive at the Proseal GT1 machine filled, with level product and the clip on lid placed into position if necessary. The tray is then sealed/lidded and prepared for shipping to retailer.

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Recipe centralised in the Proseal GT1 Tray Sealing machine simplifying product change over

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Capacity for lid picking and place offering some future proofing

GT1s

THE SOLUTION

Quick automated distribution multi-head-weigher

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The Spine of the Line GT1s Vibrating tray conveyor section to level out frozen prawns Single lane OC conveyor with adjustable guides

The GT1 is automatic, large-capacity, high speed, in-line tray sealing system designed to cut labour costs.

It combines high throughput with rapid tool-changing and space saving compact design. Capable of up to 80 atmospheric packs per minute with a 4 tool impression tool.

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THE BRIEF COMPACT HIGH SPEED DESSERT LINE WITH HIGH SPEED TOOL CHANGE The customer required a compact, self-contained, high speed, sealing line to seal up to 60 dessert pots per minute. They needed multiple tools for their multiple products - rapid tool change to keep production losses due to change over to a minimum.

Proseal GT0s Tray Sealer with gas flush for extended shelf life

Load Recipe

Proseal tool storage racks with preheat 4

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Full length infeed tray guard

Tool preheat will maximise rapid tool change capability on the GT range - minimise production downtime

Four sets of tooling

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GT0s Automatic, medium-capacity, high-speed, in-line tray sealing system designed to cut labour costs. It combines high throughput with rapid tool changing and space-saving compact design.

Optional ‘free flow’ gas flush modified atmosphere packaging (MAP) available for extended shelf life. Capable of up to 36 atmospheric packs per minute with a 2 impression tool, the GT0s system is packed with used-friendly benefits including our unique Promotion modular conveyor system.

GT0s

THE DESIGN

Fill in belts smooth product transfer

Extended infeed conveyor

Out-feed extension conveyor

THE SOLUTION

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A 1.5 meter machine infeed extension ensures smooth delivery of product into Proseal GT0s tray sealer.

Proseal GT0 hermetically seals the pack with Gas Flush. The GT0s machine offers automation with a small footprint.

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Tool Preheat Storage Rack

A pre-heat station can be vital to improve overall equipment performance. A tool can be pre-heated to a user selected temperature thereby, reducing product changeover times. The pre-heat is mounted to a tool storage rack for ease of connection.

The four tool sets maximise the flexibility of the Proseal machine - tool change over takes less than 5 minutes.

A Proseal tool rack with preheat station facilities even quicker tool change as the tool is heated and ready to go once in machine .

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THE BRIEF

Cantilevered tail end for easy belt removal and wash down 1

FLEXIBLE MACHINERY ON A BUDGET This customer required a flexible solution to pack his healthy snacks that fell within a tight budget and spatial constraints and could meet a throughput of 40 packs sealed per minute. We proposed a semi-automatic, Proseal GTR machine, along with an ultra-hygienic food contact style Flat-Belt Straight Conveyor (FBSC).

Two free-standing Proseal ‘Fast Rax’ were put in place at either end to create an efficient way to fill and empty the conveyor whilst storing empty pallets underneath.

THE SOLUTION

Semi-automatic GTR system with a 4 impression tool packing up to 40 packs per minute

IP67 control box with potentiometer for speed control

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The line split into 4 stations, at station 1 half filled packs are taken from the Proseal ‘Fast Rax’ and placed on to the flat-belt conveyor, controlled by the IP67 control box.

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At station 2 the trays are pulled off the line have the sauce deposited into them then placed back onto the conveyor to move along the line.

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At station 3, trays filled with product are taken off the conveyor two at a time and sealed on the GTR machine, then placed back onto the conveyor to keep the line moving .

Semi-self-centering guide system 3

Two minute tool change for extra flexibility

Fast Rax packing system for full and empty crates

Machine on wheels for flexibility of line

Sealed product trays are crated for transport 4

GTR The Proseal GTR is a semi-automatic, two-station, rotary-table, tray sealing machine capable of up to 30 Atmospheric packs per minute with a 2 impression tool. The GTR machine is the workhorse of the ready meal and snack food industry. It is fully portable with automatic film feed. Ultra reliable and easy to operate, the GTR is used around the world and has become the benchmark for portable tray sealing equipment. The quick release tooling allows the user to change from one tray size to another in less than two minutes offering ultimate flexibility.

4

Finally, at station 4 sealed trays are taken from the end of the conveyor and put into crates ready for shipping. It is here that the controls can be set to dictate the speed of the conveyor.

GTR

THE DESIGN

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Proseal UK Ltd Adlington Industrial Estate Adlington Cheshire SK10 4NL United Kingdom T: +44 (0)1625 856 600 E: info@prosealuk.com Proseal America Inc 7611 Whitepine Road Richmond VA 23237 United States T: +1 804 447 9038 E: info@prosealamerica.com Proseal Australia PTY Ltd 24-26 Lindon Court Tullamarine Victoria 3043 Australia T: +61 (0) 3 9397 0955 E: info@prosealaustralia.com For a list of our global distributors please visit our website: www.proseal.com

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GT6ex-Twin

Page 4

GT5e

Page 6

GT4e

Page 8

GT2sx-Twin

Page 10

GT2X-Twin

Page 12

GT2s

Page 14

GT1s

Page 16

GT0s

Page 18

GTR

Proseal UK LTD Adlington Industrial Estate Adlington Cheshire SK10 4NL Tel: 01625 856600 Fax: 01625 856611

e-mail: info@prosealuk.com Web: www.prosealuk.com

Proseal UK Ltd owns the copyright of this drawing which has been supplied in confidence. It therefore must not be usedfor any other purpose than that for which it has been supplied. Furthermore it must not be copied or disclosed (in whole or part) without the written permission of ProsealUK Ltd.

ALL DIMENSIONS IN MM ALL TOLERANCES TO +0.1 MM UNLESS OTHERWISE STATED

3RD ANGLE

ALL EDGED TO BE CNC PROGRAMMED OR DEBURRED WITH A 0.5MM X 45Ëš FILLET

SHEET SIZE

TITLE

DATE DRAWN

A4

DRAWN BY

Page 20 PROSEAL PROJECTS BROCHURE

2018

SCALE

DWG NO.

INDEX

REVISION

2