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The food industry is aware of current public concerns related to packaging
which includes:
• Packaging litter and the volume of packaging waste in municipal waste.
• Cost of disposal and recovery of discarded packaging in municipal waste.
• Pollution associated with methods of disposal, i.e. landfill and incineration.
• Ease of opening.
• Perception of over-packaging due to apparently excessive ullage (free space) resulting from
product settlement.
• Legibility of labels.
• Integrity of information on labels.
• Contamination of food due to the packaging itself.
• Accidents involving packaging.
Framework for a packaging strategy
 Technical requirements of the product and its packaging to ensure pack functionality
and product protection/preservation throughout the pack’s shelf life during
distribution and storage until its consumption.
 Customer’s valued packaging and product characteristics, for example, aesthetic,
flavor, convenience, functional and environmental performance.
 Marketing requirements for packaging and product innovation to establish a distinct
(product/service) brand proposition; protect brand integrity and satisfy anticipated
demand at an acceptable profit in accordance with marketing strategy.
 Supply chain considerations such as compatibility with existing pack range and/or
manufacturing system.
 Legislation and its operational/financial impacts, for example, regulations regarding
food hygiene, labeling, weights and measures, food contact materials, due diligence
etc.
 Environmental requirements or pressures and their impacts, for example, light-
weighting to reduce impact of taxes or levies on amount of packaging used.
1.Vacuum packaging machine
Vacuum packaging is a method of packaging that removes air from the package prior to
sealing. This method involves (manually or automatically) placing items in a plastic film
package, removing air from inside, and sealing the package. A vacuum packaging machine
consists of vacuum pumps, motors, vacuum chamber, sealing section, Plexiglas plate covers,
air bag, and the electromagnetic valve.
Advantages  Reduces spoilage  Efficiency  Freshness  Safety  Money Savings
Equipment use In Vacuum Packaging:
• External vacuum sealers - external vacuum sealers involve a bag being attached to the
vacuum-sealing machine externally. The machine will remove the air and seal the bag, which
is all done outside the machine.
• Vacuum chamber machines - single chamber sealers require the entire product to be
placed within the machine. The lid is closed and air is removed. Then, there is a heat seal
inside the chamber that will seal the bag. After sealing the bag the chamber is refilled with air
by the automatic opening of a vent to the outside. The lid is then opened and the product
removed.
• Double vacuum chamber machines - they are simply a pair of chambers with two seal
bars to seal the pouch. The air is pulled from the entire chamber during the vacuum process,
the bag is sealed and then the air is let back in the chamber.
• Automatic belt vacuum chamber machines - automatic belt chamber sealers require the
entire product to be placed in a plastic bag or pouch within the machine. The product travels
on the conveyor belt, it is automatically positioned in the machine on the seal bar, the lid is
closed and air is removed.
Advantages
Sealed foods last 3-5 times longer compared to conventional storage methods. as a result,
foods maintain their texture and appearance longer.
• Store food using vacuum sealed foods is in the freezer. Freezer burn is eliminated, because
foods no longer become dehydrated from contact with cold, dry air.
•One of the best aspects of this storage method is that it is extremely economical.
• Vacuum sealing conserves space for food storage.
•Packing to protect against handling for hygiene during transport and presentation
Disadvantages
 If you are storing bulky food items, or foods that have sharp corners, during the
oxygen removing process, these sharp corners can puncture the bags.
 Vacuum sealing is the bags are not completely impervious to air, so after a couple
years, they begin to leak. When leaks occur, the opened seals allow oxygen, insects
and other enemies of your food to enter.
2.Form Fill and Seal Machines
Collar Type Vertical Form Fill and Seal Machine
• Vertical Form Fill and Seal Machine
• Horizontal Form Fill and Seal Machine (Flow Wrapping)
• Filling Machine
• Semi-Automatic Filling and Sealing Machine
Vertical form fill and seal machine
The Vertical Form Fill & Seal (VFFS) application is a way of packaging that
vertically forms a tube (pouch), fills the pouch with product, and then seals the
pouch. These types of applications are usually in the primary packaging area of a
packaging line, where machines take finished products and put them in a
package. Vertical Form, Fill, and Seal (VFFS) machines are used in the consumer products
industry for a wide variety of packaging applications. Various products like salt,
tea, sugar, spices, snack foods, wafers, detergent, and candies are placed into
formed pouches and then sealed.
Working principles
• A 3- phase squirrel cage induction motor is used.
• Two rubber belts pull the film which is in the form cylindrical shape is pulled towards
downward.
• The vertical sealing bar controlled by pneumatic piston will seal the edge of the film by
melting the edge together.
• A blade is also attached to the one of the horizontal sealing bar which is powered by a small
pneumatic piston.
How Do VFFS Machines Work?
VFFS machines offer businesses a fast and efficient way of packaging their products. A roll
of plastic film is fed through the machine’s long, hollow conical tube, where the outer edges
of are sealed together to form a bag. Then, a horizontal sealing bar clamps across the bottom
edge of the plastic, sealing those pieces together. This bag is the lowered onto a weighing
table, where the product is filled into the bag, and when the target weight of the bag is
reached, the filling stops and the horizontal sealing bar seals the top of the bag, and that bag
is cut away from the rest of the roll, ready to advance onward in the packaging line. During
the sealing process, the bag may be filled with air from an inert gas supply. This helps protect
the product from crushing—take, for instance, a bag of potato chips—and drives out oxygen,
which can prevent or slow the growth of bacteria.
Advantages
 Completely automated forming, filing & bag sealing process from start to finish.
 Speeds up the bagging process & in turn output.
 It increase overall sealing & bagging precision.
 Delivers high quality packaging products at low cost.
 Fast, durable & reliable packaging.
 Significant packaging cost reduction due to ease of use & highly efficient machinery.
 Require less labors.
Dis-advantages
 Only produce a pillow style pouch and it has a seam (where the lay-flat roll-stock is
joined and sealed) running the length of the bag.
 Trained person required.
Horizontal Form Fill and Seal Machine
• Any type of pouch (three sides, four sides, center seal, stand up, zipper etc) can be sealed.
• Pouch moves in horizontal position.
• Continuous type sealing process for more production.
• Conveyor speed 5 to 12 meters per min.
• Teflon belts are used for sealing.
3.Cup Fillers (Also known as Pocket Fillers)
Cup fillers are also volumetric fillers that work in a different way than an auger filler. If you
imagine a measuring cup where you level off the cup with a straight blade, you have an
understanding of how a cup filler works. Cup fillers work well with any free flowing product
such as nuts, granules, and course powders and can be found in reciprocating and rotary
styles. Cup fillers are also the machine of choice for canning operations of peas, corn, beans
and many other similar products. A hopper sits above the top of the cup and gravity feeds
product in. Wipers remove excess product so that the cup is leveled. When the cup reaches
the discharge chute it falls out of the bottom of the cup and into the container or bag. Cup
fillers can be made for very high production rates compared to auger and net weight fillers.
Working Principle:
Cup fillers are an economical alternative for volumetric filling of free flowing products. The
concept is actually quite simple if you imagine dipping your measuring cup into product and
then leveling it with a straight edged knife. This is the basic principle behind a cup filler
except that the product flows from a hopper above and the knife is the edge of the hopper.
For lower speed applications pocket fillers are often reciprocating devices. But higher speed
cup filling equipment utilizes rotary systems that can be scaled up to match almost any speed
requirement.
Advantages of Cup Fillers
 Can run virtually any free flowing product (not recommended for fine powders).
 Fast - Capable of speeds into the hundreds of fills per minute.
 Simple design - very little downtime for mechanical problems.
 Relatively inexpensive to other filling systems.
Disadvantage of Cup Fillers
 Very limited fill range without change parts (less than 2:1).
 Cannot run products that are not very free flowing.
 Does not run irregular shapes or densities.
4.Automatic water Bottling machine
The machines are mainly used in the mineral and pure water filling operations. The three
functions of bottle rinsing, filling and capping are composed in one body of the machine.The
whole process is automatic. The machine is also used in filling juices, mineral water and
purified water in bottles made of polyester and plastics. The machine can also be used in hot
filling if being installed with temperature controlling device. The handle of the machine can
be freely and conveniently turned to adjust the machine to fill various types of bottles. The
filling operation is faster and more stable because the micro pressure filling operation of the
new type is adopted. There the output and benefit of the machine is higher than the machines
of the same specifications. The advanced OMRON programmed controller (PLC) is adopted
to control the machine to run automatically while a transducer is used in the bottle -entering
chains to adjust speeds and coordinated with the transducer of the main machine to make the
operations of moving bottle forward steadily and reliable . It is convenient to operate with
higher automation because every part of the machine is inspected to run with photo
electricity, On the bases, the filling parts of the machine can be changed into filling methods
of lower vacuum.
Working principle:
According to the photo, when the bottle is transferred to the machine through conveyor
continuously. The bottle is transferred through air conveyor at first, then to rinser. The
machine start to rinse through the bottle nip clamping and turning over 180 degree. The bottle
turn over to origin after rinsing. Then the machine start to fill through the middle gear wheel
1. After finish the filling, the machine start to cap through the middle gear wheel II. At the
same time, the caps are fed to the bottom of bottle through cap feeding. So capping is
performing. The machine will start to the next working procedure after the bottle is
transferred to the conveyor belt.
Advantages
 Extensive applicability: the machine adopt full locking neck operation mode, you may
adjust the height of the conveyor link carton when producing all kinds of bottle shape.
So it is available for the bottle, the height is 150-310mm and the neck is 50-90 mm.
 The capacity can be adjusted continuously: the machine adopt frequent timing, stable
and reliable.
 The machine is of perfect and reliable safe protection system, it is easy to protect the
machine and the operation.
5.Pharmaceutical processing equipment
Blister Packaging Machine
The four basic components of pharmaceutical blister packages are;
 The forming film (Forming films account for approximately 80–85% of the blister
package
 The lidding material (lidding materials make up 15–20% of the total weight of the
package.
 Heat seal coating.
 And the printing ink
Working principle:
• In pharmaceutical industry Blister Packaging Machines are used for the packing tablets,
capsules, pills and other similar products packing.
• The packing process start with the capsules or tablets being loaded into a hopper and then
into a feeder, which in turn can either be linear feeder or a brush box feeder depending on the
shape of the product and also the material to be used.
• Heated rollers in the machine use different plastic films to form blisters that are
subsequently filled with tablets.
• Some machines make use of alluminium foil to form blisters.
• Machines are manufactured according to the size, depth and material used to form blisters.
• After tablets have been inserted in the formed blisters, cavities are heat sealed using foil.
• Blister Sealing Machines are used to seal filled plastic blister to a piece of coated carton
board, by heat.
• The blister is kept in the sealing die which has the same shape as that of the cavity. The
cavities are then filled and sealed by a foil using heat.
• Blister Trimming Machines are used for cutting, trimming the sealed blister or formed
blister pack.
Advantages of blister packaging:
 Prevention of broken glass bottles.
 Reduced costs and higher packaging speeds relative to other packaging materials.
 Blister packaging helps retain product integrity because drugs that are prepackaged in
blisters are shielded from adverse conditions.
 Furthermore, opportunities for product contamination are minimal.
 And each dose is identified by product name, lot number, and expiration date.
 Blister packaging protects pharmaceuticals in the home better than bottles do.
 Tamper evidence is another strength of blister packaging. The dosage units are
individually sealed in constructionsof plastic, foil, and/or paper. With blister
packaging, however, each tablet or capsule is individually protected from tampering
until use, so any form of tampering with a blister package is immediately visible.
Dis-advantages:
 The protective properties are not strong because of the PVC`s poor barrier against
moisture & oxygen ingress.
 Not suitable for light sensitive drugs because of the transparency of PVC.
Capsule Filling Machine
 High Speed Automatic Capsule Filling machines are suitable for filling powders and
pellets.
 These are versatile machines with several outstanding features both functional and
mechanical.
 The machines have capabilities to give an output of 40,000 capsules and 90,000
capsules per hour with high filling accuracy and can accommodate capsule sizes.
 Capsule fillers are used to fill hard gelatin and non-gelatin capsules with pre-
determined quantity of liquids, powders, pellets, tablets.
 Capsules are normally fed into the machine, the filler then align, opens and accurately
fills each capsule and recloses.
 Fillers generate minimum dust with lowest level of product loss. Non-separated,
double loaded capsules and improperly inserted capsules are automatically rejected by
machines to maintain the consistency in the quality of product.
 Most capsule fillers are characterized with fast changeover time to accommodate
variety of capsules in terms of shapes and size.
Advantages:
• High Quality Capsule Filling Machine requires minimal maintenance and easy to clean.
• Another important feature is the installation of speed adjusting equipment and automatic
counters ensuring the right quantity of capsules being filled and packed.
Dis-advantages
 Hygroscopic drugs cannot be processed because they absorb water.
6.Drying machine
Introduction:
Drying machine adopts circulating hot air to dry vegetables. The dryer is equipped with low
noise, high temperature resistant axial flow fan and automatic temperature control system.
The whole circulation system is fully closed, hottest air circulates in the oven, having high
thermal efficiency and saving energy. The vegetable drying machine is suitable for drying
various kinds of vegetables, such as radish, potato, sweet potato, mushroom, chili, garlic,
ginger, long beans, cauliflower, bamboo fungus, bamboo shoots, etc. and the nutrition values
of vegetables can be retained after drying.
Advantages:
1. Utilizing forced ventilation function and adjustable air distribution plates, ensuring
temperature balance in the oven.
2. Multiple heat sources for your choice: steam, electricity, or electricity-steam dual-use
3. Automatic constant temperature control, automatic alarm over limit, reliable operation.
4. The inner wall of the dryer machine are fully welded and adopt circular arc transition at all
transitions, no dead angle, easy to clean.
5. Unique guide rail sealing device, ensuring the sealing performance of the vegetable dryer,
helping thermal insulation and prevent pollution.
6. Adopt filters at the air inlet and outlet, ensuring cleanliness of the circulating air.
7. All the spare parts in the oven can be disassembled and assembled quickly, easy for clean
and maintenance.
8. The vegetable dryer machine is in compliance with GMP requirements.
9. Uniform trolley size and tray size. Baking tray dimensions: 640*460*45mm. 10. The oven
dryer can be customized according to your requirement.
Working Principle:
Hot air circulating oven adopts steam or electricity as heat source, and axial flow fan to
circulate air. After heated by the radiator or electric heater, the hot air delivered by the
circulating fan enters into the drying room through the air duct, and transfers heat to the
materials. Fresh air is replenished through the air inlet while wet air is discharged through the
air outlet. By the constant replenishing of fresh air and discharging of wet air, the proper
relative humidity in the drying oven is maintained.
Application :
1. Different types of vegetable drying.
2. Removing moisture from fruits.
3. Lowering water activity
4. Ensuring increased shelf-life.
7.Labeling Machines
Labelling Machines apply labels and decoration onto all types of packaging containers,
display, point-of-sale and transit packs.
Advantages of labeling
Labeling, just like the rest of the packaging processes, is very important for the product.
1) A label has the ability to attract a consumer,
2) Provides information on the product
3) Allows consumers to differentiate and identify with the product.
4) Labels are also used to provide protection against tampering (tamper evident) to ensure
the product reaches the consumer without interference and unopened.
5)Shrink sleeve labels are also used on products which do not have surfaces suitable for a
conventional label.
6)A growing market is security labeling to counter fraud and theft, and give brand protection
and authentication.
For ease of explanation we group labelers in several categories including: Semi-Automatic
Labeling Machines, Label Applicators, Automatic Labeling Systems, Full Body Sleeve
Labelers, and Print and Apply Labeling. Among them semi-automatic and automatic labeling
details are given below-
Semi-Automatic Labeling Machines
Semi-Automatic Wrap Labeler
Pressure Sensitive Wrap Labelers for Round Products and Bottles
Busch Machinery offers you choices for semi-automatic wrap labeling that no other company
can. From a basic hand crank model for light production needs to our very fast push through
model for labeling up to 40 bottles per minute and products up to 12" diameter. See all of our
models of bottle labelers on our semi-automatic-labeler page
Semi-Automatic Hot Melt Glue labelers for round products, bottles, cans and pails.
Another type of wrap labeler is our Hot Melt glue series. Each wrap labeling machine
features a unique skip gluing system that applies glue to the leading edge and trailing edge
(also known as the lap end when the trailing edge wraps over the leading edge of the label).
Hot Melt wrap labelers work only with sheet cut labels that are loaded into a magazine on the
machine. Three versions of Hot Melt labelers are available: ADL-200 for standard bottles
and other round products, ADL-201 designed especially for paint cans with ears where the
label is registered so that the ear holes can clear the ears on the can, and the ADL-205 Pail
labeling machine that features automatic registration of the label between the lugs.
Automatic Labeling Systems - Labeling Machines with integrated controls and product
handling
Automatic labeling systems are a step beyond simple label applicators because the labeling
heads can be integrated fully with the controls and product handling so that much higher label
application accuracy can be achieved. In fact many of the systems we offer have fully
integrated digital control systems which allows for even greater accuracy, easy setup, and fast
change over.
Examples of some standard labeling systems are: Vertical Wrap Labelers, Front and Back
Labelers, Front-Back-Wrap machines, Horizontal Wrap Labeling Machines, Top and Bottom
labelers, Top Labelers, and Bottom Labelers, all of which are for pressure sensitive labeling
applications.
8.Automatic wrapping machine
Wrapping Machines wrap a flexible packaging material, (e.g. paper, aluminium, plastic film),
around a product or group of products.
Working principle
Bottles or boxes needing to be packed, through bottle conveying organ, get to bottle blocking
board along route way formed by bottle distributing board. Top photoelectric detecting head
sends signal and front bottle conveying machine stops and bottle blocking board stands back
to make bottles press and produce stress release. Bottle distributing board descends and bottle
partition-pressing board descends to compartmentalize bottles being wrapped and bottles
waiting to be wrapped. Bottle pushing organ goes ahead to make bottles together with film to
get to shrinking and cutting position along bottle guiding organ, at the same time, push
bottles wrapped last time to conveyor of heat shrinking equipment, at this moment, film
delivering organ works simultaneously. Then film pressing cylinder acts downwards and
pushes film and then heat cutting reamer acts upwards to fulfill cutting function. Bottles
pushed to high temperature conveyor go ahead and fulfill heat shrinking function at the same
time in heat shrinking equipment, finally cooled with cold wind and shrunk, get to finished
products carrying device. Above process acts repeatedly to achieve wrapping automation.
Advantages of wrapping
1)Because wrapping is so versatile it is used in many sectors, however, it is most common in
food, bakery and confectionery for single items which can range from confectionery (count
line), bars and cakes through to cheese and sausages.
2)There are so many applications of this packaging technique for single items it would be
difficult to exclude any particularly for some products in daily use items, DIY or toiletries
and cosmetics. Some techniques are used in very particular product areas e.g. skin packaging
for DIY products and high quality fold wrapping for cosmetics, CDs or cigarettes.
3) Many single item wrappers can handle products at very high speeds, particularly in the
confectionery sector.
4) When wrapping is used for larger items or units or for grouping single products in
multipacks for point of sale, or in larger numbers for transportation, then speeds tend to be
slower. However some applications in the beverage sector can achieve reasonable speeds to
match demand from the speed of other machines in the line.
9.Sterilization Machines
Sterilization machines can also be called, Autoclaves and Retorts. There three main types of
sterilising system; static, rotary and pilot or laboratory systems.
General Characteristics :-
 Steam-Water spray mix.
 Top shower for cans and glass jars plus side shower for pouches and trays
 Indirect cooling system by heat exchanger allows water recovery.
 All vessel, pipe work and valves and heat exchanger in stainless steel materials
 Insulated shell with mirror polished stainless steel cladding
 PLC control with modem connection allows remote troubleshooting and servicing
 Process monitoring in the operator interface with complete information of
temperature, pressure, time and flow
 Easy product recipe setup with password protected access
 Optimum heat distribution (+/-0,5 ºC)
 Accurate pressure control (+/- 0,05 bar)
10.Filling Equipment and Machinery
There are many types of filling machines used to package the variety of products in today's
marketplace including liquids, pastes, chunky products, powders, granules, tablets, capsules,
etc. Most filling machines are available from semi-automatic table top versions all the way
up to high speed production line machines, including rotary fillers.
Liquid Level Filling Machines
Overflow Pressure Filler
In order to speed up the process of filling we have the pressure filling machine. Pressure
fillers have a tank on the back of the machine with a valve to keep the tank full either by a
simple float valve or by switching a pump on and off. The tank flood feeds a pump which
then feeds to a manifold where a number of special overflow filling heads lower down into
the bottle as the pump switches on forcing liquid into the bottles at a speedy rate. As the
bottle fills to the top, and excess liquid goes back up a second port within the filling head and
overflows back into the tank. At that point the pump switches off and any remaining excess
liquid and pressure is relieved. Heads come up, bottles index out and repeat the process.
Pressure fillers can be configured for semi-automatic, automatic inline filling systems or as
rotary pressure fillers for higher speeds.
Overflow Pressure Filling Machine
Volumetric Filling Machines
Rotary Valve Piston Filling Machine
Rotary valve piston fillers are distinguished by the rotary valve which has a large throat
opening to allow thick products and products with large particulates (up to 1/2" diameter)
from the supply hopper to flow through unimpeded. Great as a tabletop model or can be
ganged for higher production requirements. Fill pastes, peanut butter, gear oil, potato salads,
Italian dressing and much more on this type of piston filler with accuracy of plus or minus
one-half percent. Fills accurately at a ten to one ratio of the cylinder set.
Rotary Valve Piston Filling Machine
Volumetric Filling Machine vs. Liquid Level Fillers
There are very few bottles that don't have some small differences in volume. Considering
that fact is very important in deciding the type of filling system you are going to use for your
packaging. You've probably noticed at the supermarket or auto store that when you look at
fill level, some of the bottles seem to look like they are short fills compared to others.
Chances are they were filled with a volumetric filler. The volume inside the bottle is correct,
but because of the small volumetric difference between the bottles it appears to be short. With
a liquid level filling machine all of the bottles will "appear" to have the same volume because
the fill level will be the same, but in actuality there will be slight differences in fill volume,
no short fills, but some slight overfills.
Volumetric or Liquid Level?
For the vast majority of products the answer will be liquid level filling since it is cheaper and
faster than volumetric filling, plus consumers of the product will not feel cheated when the
bottles "appear" to be evenly filled. However volumetric filling is the best solution if the
product has to have an exact dosage for it's use or if the product is very expensive per ounce
and the little bit of giveaway could cost you dearly, especially in a high production
environment.
11.Coding, Printing and Marking Systems
Today's modern packaging environment offers a number of choices for marking, coding and
printing lot codes, barcodes, 2D codes, serial numbers, and contents in the form of labels or
direct printing on manufactured products, the packaging that contains them and the final box
and pallet labeling or marking to identify a shipment. All of this is accomplished by the
utilization of industrial ink jet coders, hot stamp coders, label printers, and combination print
and apply equipment. In this regard the modernization of the packaging machinery industry is
the most evident compared to the days when all marking was by contact or stencil.
Industrial Ink Jet Coder
One aspect of industrial inkjet printers that is the same for all types is that they all depend on
a product moving in front of the print head in a constant motion, since the print head is
basically noting more that a vertical line of nozzles that turn on and off at very high speeds as
the product passes in front of it, thus producing the characters or image we wish to reproduce.
But that similarity quickly vanishes because the three types of ink jet coders have vastly
different capabilities in terms of speed, height, number of lines, and resolution of the
characters and images. The differences are further delineated by the types of inks that can be
run on the inkjet printing system which can limit its applicability depending on the substrate
to be marked. In order to categorize the industrial ink jet coder further we divide the three
types of inkjet coders, CIJ (continuous ink jet), DOD (drop on demand), and cartridge into
two categories: Small Character ink jet coder and Large Character ink jet coder.
Small Character Ink Jet Coder
While there is some blurring of these lines, at Busch Machinery we define a small character
inkjet coder as being capable of printing at least two lines of information in a selectable font
size down to at least 1/16" height, or one line up to 12 mm height (0.47") and has the
capability of printing at least some versions of barcodes. CIJ ink jet coders are the best for
virtually any application, but cartridge systems can work well on porous and semi-porous
surfaces for much lower cost.
Large character ink jet coder
A Large Character Ink Jet Coder is defined a capable of printing a single line from 12 mm
height to nearly 4 inches high on a single print head (nearly 8" when doubled up). Beyond
that there are two categories of large character inkjet printing: high resolution and low
resolution.
High Resolution Large Character Industrial Inkjet Printers
With the improvement in inks and inkjet technology it is now possible to print on corrugated
and other large surfaces with 300 dpi resolution in wide swaths of up to 4" high on a single
printhead, and up to 8" with dual print heads. Furthermore inks are available that allow
printing on virtually any surface. A great way to eliminate more expensive print and apply
labeling systems with their higher initial and operating costs. Print text, graphics, and
barcodes with 99.9% readability!
High Resolution Large Character Industrial Inkjet Printers

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Food Packaging and Machinery

  • 1. The food industry is aware of current public concerns related to packaging which includes: • Packaging litter and the volume of packaging waste in municipal waste. • Cost of disposal and recovery of discarded packaging in municipal waste. • Pollution associated with methods of disposal, i.e. landfill and incineration. • Ease of opening. • Perception of over-packaging due to apparently excessive ullage (free space) resulting from product settlement. • Legibility of labels. • Integrity of information on labels. • Contamination of food due to the packaging itself. • Accidents involving packaging. Framework for a packaging strategy  Technical requirements of the product and its packaging to ensure pack functionality and product protection/preservation throughout the pack’s shelf life during distribution and storage until its consumption.  Customer’s valued packaging and product characteristics, for example, aesthetic, flavor, convenience, functional and environmental performance.  Marketing requirements for packaging and product innovation to establish a distinct (product/service) brand proposition; protect brand integrity and satisfy anticipated demand at an acceptable profit in accordance with marketing strategy.  Supply chain considerations such as compatibility with existing pack range and/or manufacturing system.  Legislation and its operational/financial impacts, for example, regulations regarding food hygiene, labeling, weights and measures, food contact materials, due diligence etc.  Environmental requirements or pressures and their impacts, for example, light- weighting to reduce impact of taxes or levies on amount of packaging used.
  • 2. 1.Vacuum packaging machine Vacuum packaging is a method of packaging that removes air from the package prior to sealing. This method involves (manually or automatically) placing items in a plastic film package, removing air from inside, and sealing the package. A vacuum packaging machine consists of vacuum pumps, motors, vacuum chamber, sealing section, Plexiglas plate covers, air bag, and the electromagnetic valve. Advantages  Reduces spoilage  Efficiency  Freshness  Safety  Money Savings Equipment use In Vacuum Packaging: • External vacuum sealers - external vacuum sealers involve a bag being attached to the vacuum-sealing machine externally. The machine will remove the air and seal the bag, which is all done outside the machine. • Vacuum chamber machines - single chamber sealers require the entire product to be placed within the machine. The lid is closed and air is removed. Then, there is a heat seal inside the chamber that will seal the bag. After sealing the bag the chamber is refilled with air by the automatic opening of a vent to the outside. The lid is then opened and the product removed. • Double vacuum chamber machines - they are simply a pair of chambers with two seal bars to seal the pouch. The air is pulled from the entire chamber during the vacuum process, the bag is sealed and then the air is let back in the chamber. • Automatic belt vacuum chamber machines - automatic belt chamber sealers require the entire product to be placed in a plastic bag or pouch within the machine. The product travels on the conveyor belt, it is automatically positioned in the machine on the seal bar, the lid is closed and air is removed.
  • 3. Advantages Sealed foods last 3-5 times longer compared to conventional storage methods. as a result, foods maintain their texture and appearance longer. • Store food using vacuum sealed foods is in the freezer. Freezer burn is eliminated, because foods no longer become dehydrated from contact with cold, dry air. •One of the best aspects of this storage method is that it is extremely economical. • Vacuum sealing conserves space for food storage. •Packing to protect against handling for hygiene during transport and presentation Disadvantages  If you are storing bulky food items, or foods that have sharp corners, during the oxygen removing process, these sharp corners can puncture the bags.  Vacuum sealing is the bags are not completely impervious to air, so after a couple years, they begin to leak. When leaks occur, the opened seals allow oxygen, insects and other enemies of your food to enter. 2.Form Fill and Seal Machines Collar Type Vertical Form Fill and Seal Machine • Vertical Form Fill and Seal Machine • Horizontal Form Fill and Seal Machine (Flow Wrapping) • Filling Machine • Semi-Automatic Filling and Sealing Machine Vertical form fill and seal machine The Vertical Form Fill & Seal (VFFS) application is a way of packaging that vertically forms a tube (pouch), fills the pouch with product, and then seals the pouch. These types of applications are usually in the primary packaging area of a packaging line, where machines take finished products and put them in a package. Vertical Form, Fill, and Seal (VFFS) machines are used in the consumer products industry for a wide variety of packaging applications. Various products like salt, tea, sugar, spices, snack foods, wafers, detergent, and candies are placed into formed pouches and then sealed. Working principles • A 3- phase squirrel cage induction motor is used. • Two rubber belts pull the film which is in the form cylindrical shape is pulled towards downward.
  • 4. • The vertical sealing bar controlled by pneumatic piston will seal the edge of the film by melting the edge together. • A blade is also attached to the one of the horizontal sealing bar which is powered by a small pneumatic piston. How Do VFFS Machines Work? VFFS machines offer businesses a fast and efficient way of packaging their products. A roll of plastic film is fed through the machine’s long, hollow conical tube, where the outer edges of are sealed together to form a bag. Then, a horizontal sealing bar clamps across the bottom edge of the plastic, sealing those pieces together. This bag is the lowered onto a weighing table, where the product is filled into the bag, and when the target weight of the bag is reached, the filling stops and the horizontal sealing bar seals the top of the bag, and that bag is cut away from the rest of the roll, ready to advance onward in the packaging line. During the sealing process, the bag may be filled with air from an inert gas supply. This helps protect the product from crushing—take, for instance, a bag of potato chips—and drives out oxygen, which can prevent or slow the growth of bacteria. Advantages  Completely automated forming, filing & bag sealing process from start to finish.  Speeds up the bagging process & in turn output.  It increase overall sealing & bagging precision.  Delivers high quality packaging products at low cost.  Fast, durable & reliable packaging.  Significant packaging cost reduction due to ease of use & highly efficient machinery.  Require less labors. Dis-advantages  Only produce a pillow style pouch and it has a seam (where the lay-flat roll-stock is joined and sealed) running the length of the bag.  Trained person required.
  • 5. Horizontal Form Fill and Seal Machine • Any type of pouch (three sides, four sides, center seal, stand up, zipper etc) can be sealed. • Pouch moves in horizontal position. • Continuous type sealing process for more production. • Conveyor speed 5 to 12 meters per min. • Teflon belts are used for sealing. 3.Cup Fillers (Also known as Pocket Fillers) Cup fillers are also volumetric fillers that work in a different way than an auger filler. If you imagine a measuring cup where you level off the cup with a straight blade, you have an understanding of how a cup filler works. Cup fillers work well with any free flowing product such as nuts, granules, and course powders and can be found in reciprocating and rotary styles. Cup fillers are also the machine of choice for canning operations of peas, corn, beans and many other similar products. A hopper sits above the top of the cup and gravity feeds product in. Wipers remove excess product so that the cup is leveled. When the cup reaches the discharge chute it falls out of the bottom of the cup and into the container or bag. Cup fillers can be made for very high production rates compared to auger and net weight fillers. Working Principle: Cup fillers are an economical alternative for volumetric filling of free flowing products. The concept is actually quite simple if you imagine dipping your measuring cup into product and then leveling it with a straight edged knife. This is the basic principle behind a cup filler except that the product flows from a hopper above and the knife is the edge of the hopper. For lower speed applications pocket fillers are often reciprocating devices. But higher speed
  • 6. cup filling equipment utilizes rotary systems that can be scaled up to match almost any speed requirement. Advantages of Cup Fillers  Can run virtually any free flowing product (not recommended for fine powders).  Fast - Capable of speeds into the hundreds of fills per minute.  Simple design - very little downtime for mechanical problems.  Relatively inexpensive to other filling systems. Disadvantage of Cup Fillers  Very limited fill range without change parts (less than 2:1).  Cannot run products that are not very free flowing.  Does not run irregular shapes or densities. 4.Automatic water Bottling machine The machines are mainly used in the mineral and pure water filling operations. The three functions of bottle rinsing, filling and capping are composed in one body of the machine.The whole process is automatic. The machine is also used in filling juices, mineral water and purified water in bottles made of polyester and plastics. The machine can also be used in hot filling if being installed with temperature controlling device. The handle of the machine can be freely and conveniently turned to adjust the machine to fill various types of bottles. The filling operation is faster and more stable because the micro pressure filling operation of the new type is adopted. There the output and benefit of the machine is higher than the machines of the same specifications. The advanced OMRON programmed controller (PLC) is adopted
  • 7. to control the machine to run automatically while a transducer is used in the bottle -entering chains to adjust speeds and coordinated with the transducer of the main machine to make the operations of moving bottle forward steadily and reliable . It is convenient to operate with higher automation because every part of the machine is inspected to run with photo electricity, On the bases, the filling parts of the machine can be changed into filling methods of lower vacuum. Working principle: According to the photo, when the bottle is transferred to the machine through conveyor continuously. The bottle is transferred through air conveyor at first, then to rinser. The machine start to rinse through the bottle nip clamping and turning over 180 degree. The bottle turn over to origin after rinsing. Then the machine start to fill through the middle gear wheel 1. After finish the filling, the machine start to cap through the middle gear wheel II. At the same time, the caps are fed to the bottom of bottle through cap feeding. So capping is performing. The machine will start to the next working procedure after the bottle is transferred to the conveyor belt. Advantages  Extensive applicability: the machine adopt full locking neck operation mode, you may adjust the height of the conveyor link carton when producing all kinds of bottle shape. So it is available for the bottle, the height is 150-310mm and the neck is 50-90 mm.  The capacity can be adjusted continuously: the machine adopt frequent timing, stable and reliable.  The machine is of perfect and reliable safe protection system, it is easy to protect the machine and the operation.
  • 8. 5.Pharmaceutical processing equipment Blister Packaging Machine The four basic components of pharmaceutical blister packages are;  The forming film (Forming films account for approximately 80–85% of the blister package  The lidding material (lidding materials make up 15–20% of the total weight of the package.  Heat seal coating.  And the printing ink Working principle: • In pharmaceutical industry Blister Packaging Machines are used for the packing tablets, capsules, pills and other similar products packing. • The packing process start with the capsules or tablets being loaded into a hopper and then into a feeder, which in turn can either be linear feeder or a brush box feeder depending on the shape of the product and also the material to be used. • Heated rollers in the machine use different plastic films to form blisters that are subsequently filled with tablets. • Some machines make use of alluminium foil to form blisters. • Machines are manufactured according to the size, depth and material used to form blisters. • After tablets have been inserted in the formed blisters, cavities are heat sealed using foil. • Blister Sealing Machines are used to seal filled plastic blister to a piece of coated carton board, by heat. • The blister is kept in the sealing die which has the same shape as that of the cavity. The cavities are then filled and sealed by a foil using heat. • Blister Trimming Machines are used for cutting, trimming the sealed blister or formed blister pack.
  • 9. Advantages of blister packaging:  Prevention of broken glass bottles.  Reduced costs and higher packaging speeds relative to other packaging materials.  Blister packaging helps retain product integrity because drugs that are prepackaged in blisters are shielded from adverse conditions.  Furthermore, opportunities for product contamination are minimal.  And each dose is identified by product name, lot number, and expiration date.  Blister packaging protects pharmaceuticals in the home better than bottles do.  Tamper evidence is another strength of blister packaging. The dosage units are individually sealed in constructionsof plastic, foil, and/or paper. With blister packaging, however, each tablet or capsule is individually protected from tampering until use, so any form of tampering with a blister package is immediately visible. Dis-advantages:  The protective properties are not strong because of the PVC`s poor barrier against moisture & oxygen ingress.  Not suitable for light sensitive drugs because of the transparency of PVC. Capsule Filling Machine  High Speed Automatic Capsule Filling machines are suitable for filling powders and pellets.  These are versatile machines with several outstanding features both functional and mechanical.  The machines have capabilities to give an output of 40,000 capsules and 90,000 capsules per hour with high filling accuracy and can accommodate capsule sizes.  Capsule fillers are used to fill hard gelatin and non-gelatin capsules with pre- determined quantity of liquids, powders, pellets, tablets.  Capsules are normally fed into the machine, the filler then align, opens and accurately fills each capsule and recloses.  Fillers generate minimum dust with lowest level of product loss. Non-separated, double loaded capsules and improperly inserted capsules are automatically rejected by machines to maintain the consistency in the quality of product.  Most capsule fillers are characterized with fast changeover time to accommodate variety of capsules in terms of shapes and size. Advantages: • High Quality Capsule Filling Machine requires minimal maintenance and easy to clean. • Another important feature is the installation of speed adjusting equipment and automatic counters ensuring the right quantity of capsules being filled and packed. Dis-advantages  Hygroscopic drugs cannot be processed because they absorb water.
  • 10.
  • 11. 6.Drying machine Introduction: Drying machine adopts circulating hot air to dry vegetables. The dryer is equipped with low noise, high temperature resistant axial flow fan and automatic temperature control system. The whole circulation system is fully closed, hottest air circulates in the oven, having high thermal efficiency and saving energy. The vegetable drying machine is suitable for drying various kinds of vegetables, such as radish, potato, sweet potato, mushroom, chili, garlic, ginger, long beans, cauliflower, bamboo fungus, bamboo shoots, etc. and the nutrition values of vegetables can be retained after drying. Advantages: 1. Utilizing forced ventilation function and adjustable air distribution plates, ensuring temperature balance in the oven. 2. Multiple heat sources for your choice: steam, electricity, or electricity-steam dual-use 3. Automatic constant temperature control, automatic alarm over limit, reliable operation. 4. The inner wall of the dryer machine are fully welded and adopt circular arc transition at all transitions, no dead angle, easy to clean. 5. Unique guide rail sealing device, ensuring the sealing performance of the vegetable dryer, helping thermal insulation and prevent pollution. 6. Adopt filters at the air inlet and outlet, ensuring cleanliness of the circulating air. 7. All the spare parts in the oven can be disassembled and assembled quickly, easy for clean and maintenance. 8. The vegetable dryer machine is in compliance with GMP requirements. 9. Uniform trolley size and tray size. Baking tray dimensions: 640*460*45mm. 10. The oven dryer can be customized according to your requirement.
  • 12. Working Principle: Hot air circulating oven adopts steam or electricity as heat source, and axial flow fan to circulate air. After heated by the radiator or electric heater, the hot air delivered by the circulating fan enters into the drying room through the air duct, and transfers heat to the materials. Fresh air is replenished through the air inlet while wet air is discharged through the air outlet. By the constant replenishing of fresh air and discharging of wet air, the proper relative humidity in the drying oven is maintained. Application : 1. Different types of vegetable drying. 2. Removing moisture from fruits. 3. Lowering water activity 4. Ensuring increased shelf-life. 7.Labeling Machines Labelling Machines apply labels and decoration onto all types of packaging containers, display, point-of-sale and transit packs. Advantages of labeling Labeling, just like the rest of the packaging processes, is very important for the product. 1) A label has the ability to attract a consumer, 2) Provides information on the product 3) Allows consumers to differentiate and identify with the product. 4) Labels are also used to provide protection against tampering (tamper evident) to ensure the product reaches the consumer without interference and unopened. 5)Shrink sleeve labels are also used on products which do not have surfaces suitable for a conventional label. 6)A growing market is security labeling to counter fraud and theft, and give brand protection and authentication. For ease of explanation we group labelers in several categories including: Semi-Automatic Labeling Machines, Label Applicators, Automatic Labeling Systems, Full Body Sleeve Labelers, and Print and Apply Labeling. Among them semi-automatic and automatic labeling details are given below-
  • 13. Semi-Automatic Labeling Machines Semi-Automatic Wrap Labeler Pressure Sensitive Wrap Labelers for Round Products and Bottles Busch Machinery offers you choices for semi-automatic wrap labeling that no other company can. From a basic hand crank model for light production needs to our very fast push through model for labeling up to 40 bottles per minute and products up to 12" diameter. See all of our models of bottle labelers on our semi-automatic-labeler page Semi-Automatic Hot Melt Glue labelers for round products, bottles, cans and pails. Another type of wrap labeler is our Hot Melt glue series. Each wrap labeling machine features a unique skip gluing system that applies glue to the leading edge and trailing edge (also known as the lap end when the trailing edge wraps over the leading edge of the label). Hot Melt wrap labelers work only with sheet cut labels that are loaded into a magazine on the machine. Three versions of Hot Melt labelers are available: ADL-200 for standard bottles and other round products, ADL-201 designed especially for paint cans with ears where the label is registered so that the ear holes can clear the ears on the can, and the ADL-205 Pail labeling machine that features automatic registration of the label between the lugs. Automatic Labeling Systems - Labeling Machines with integrated controls and product handling Automatic labeling systems are a step beyond simple label applicators because the labeling heads can be integrated fully with the controls and product handling so that much higher label application accuracy can be achieved. In fact many of the systems we offer have fully integrated digital control systems which allows for even greater accuracy, easy setup, and fast change over. Examples of some standard labeling systems are: Vertical Wrap Labelers, Front and Back Labelers, Front-Back-Wrap machines, Horizontal Wrap Labeling Machines, Top and Bottom labelers, Top Labelers, and Bottom Labelers, all of which are for pressure sensitive labeling applications.
  • 14. 8.Automatic wrapping machine Wrapping Machines wrap a flexible packaging material, (e.g. paper, aluminium, plastic film), around a product or group of products. Working principle Bottles or boxes needing to be packed, through bottle conveying organ, get to bottle blocking board along route way formed by bottle distributing board. Top photoelectric detecting head sends signal and front bottle conveying machine stops and bottle blocking board stands back to make bottles press and produce stress release. Bottle distributing board descends and bottle partition-pressing board descends to compartmentalize bottles being wrapped and bottles waiting to be wrapped. Bottle pushing organ goes ahead to make bottles together with film to get to shrinking and cutting position along bottle guiding organ, at the same time, push bottles wrapped last time to conveyor of heat shrinking equipment, at this moment, film delivering organ works simultaneously. Then film pressing cylinder acts downwards and pushes film and then heat cutting reamer acts upwards to fulfill cutting function. Bottles pushed to high temperature conveyor go ahead and fulfill heat shrinking function at the same time in heat shrinking equipment, finally cooled with cold wind and shrunk, get to finished products carrying device. Above process acts repeatedly to achieve wrapping automation. Advantages of wrapping 1)Because wrapping is so versatile it is used in many sectors, however, it is most common in food, bakery and confectionery for single items which can range from confectionery (count line), bars and cakes through to cheese and sausages. 2)There are so many applications of this packaging technique for single items it would be difficult to exclude any particularly for some products in daily use items, DIY or toiletries and cosmetics. Some techniques are used in very particular product areas e.g. skin packaging for DIY products and high quality fold wrapping for cosmetics, CDs or cigarettes. 3) Many single item wrappers can handle products at very high speeds, particularly in the confectionery sector. 4) When wrapping is used for larger items or units or for grouping single products in multipacks for point of sale, or in larger numbers for transportation, then speeds tend to be slower. However some applications in the beverage sector can achieve reasonable speeds to match demand from the speed of other machines in the line.
  • 15. 9.Sterilization Machines Sterilization machines can also be called, Autoclaves and Retorts. There three main types of sterilising system; static, rotary and pilot or laboratory systems. General Characteristics :-  Steam-Water spray mix.  Top shower for cans and glass jars plus side shower for pouches and trays  Indirect cooling system by heat exchanger allows water recovery.  All vessel, pipe work and valves and heat exchanger in stainless steel materials  Insulated shell with mirror polished stainless steel cladding  PLC control with modem connection allows remote troubleshooting and servicing  Process monitoring in the operator interface with complete information of temperature, pressure, time and flow  Easy product recipe setup with password protected access  Optimum heat distribution (+/-0,5 ºC)  Accurate pressure control (+/- 0,05 bar) 10.Filling Equipment and Machinery There are many types of filling machines used to package the variety of products in today's marketplace including liquids, pastes, chunky products, powders, granules, tablets, capsules, etc. Most filling machines are available from semi-automatic table top versions all the way up to high speed production line machines, including rotary fillers. Liquid Level Filling Machines Overflow Pressure Filler In order to speed up the process of filling we have the pressure filling machine. Pressure fillers have a tank on the back of the machine with a valve to keep the tank full either by a simple float valve or by switching a pump on and off. The tank flood feeds a pump which then feeds to a manifold where a number of special overflow filling heads lower down into the bottle as the pump switches on forcing liquid into the bottles at a speedy rate. As the bottle fills to the top, and excess liquid goes back up a second port within the filling head and overflows back into the tank. At that point the pump switches off and any remaining excess liquid and pressure is relieved. Heads come up, bottles index out and repeat the process. Pressure fillers can be configured for semi-automatic, automatic inline filling systems or as rotary pressure fillers for higher speeds.
  • 16. Overflow Pressure Filling Machine Volumetric Filling Machines Rotary Valve Piston Filling Machine Rotary valve piston fillers are distinguished by the rotary valve which has a large throat opening to allow thick products and products with large particulates (up to 1/2" diameter) from the supply hopper to flow through unimpeded. Great as a tabletop model or can be ganged for higher production requirements. Fill pastes, peanut butter, gear oil, potato salads, Italian dressing and much more on this type of piston filler with accuracy of plus or minus one-half percent. Fills accurately at a ten to one ratio of the cylinder set. Rotary Valve Piston Filling Machine Volumetric Filling Machine vs. Liquid Level Fillers There are very few bottles that don't have some small differences in volume. Considering that fact is very important in deciding the type of filling system you are going to use for your packaging. You've probably noticed at the supermarket or auto store that when you look at fill level, some of the bottles seem to look like they are short fills compared to others. Chances are they were filled with a volumetric filler. The volume inside the bottle is correct, but because of the small volumetric difference between the bottles it appears to be short. With
  • 17. a liquid level filling machine all of the bottles will "appear" to have the same volume because the fill level will be the same, but in actuality there will be slight differences in fill volume, no short fills, but some slight overfills. Volumetric or Liquid Level? For the vast majority of products the answer will be liquid level filling since it is cheaper and faster than volumetric filling, plus consumers of the product will not feel cheated when the bottles "appear" to be evenly filled. However volumetric filling is the best solution if the product has to have an exact dosage for it's use or if the product is very expensive per ounce and the little bit of giveaway could cost you dearly, especially in a high production environment. 11.Coding, Printing and Marking Systems Today's modern packaging environment offers a number of choices for marking, coding and printing lot codes, barcodes, 2D codes, serial numbers, and contents in the form of labels or direct printing on manufactured products, the packaging that contains them and the final box and pallet labeling or marking to identify a shipment. All of this is accomplished by the utilization of industrial ink jet coders, hot stamp coders, label printers, and combination print and apply equipment. In this regard the modernization of the packaging machinery industry is the most evident compared to the days when all marking was by contact or stencil. Industrial Ink Jet Coder One aspect of industrial inkjet printers that is the same for all types is that they all depend on a product moving in front of the print head in a constant motion, since the print head is basically noting more that a vertical line of nozzles that turn on and off at very high speeds as the product passes in front of it, thus producing the characters or image we wish to reproduce. But that similarity quickly vanishes because the three types of ink jet coders have vastly different capabilities in terms of speed, height, number of lines, and resolution of the characters and images. The differences are further delineated by the types of inks that can be run on the inkjet printing system which can limit its applicability depending on the substrate to be marked. In order to categorize the industrial ink jet coder further we divide the three types of inkjet coders, CIJ (continuous ink jet), DOD (drop on demand), and cartridge into two categories: Small Character ink jet coder and Large Character ink jet coder.
  • 18. Small Character Ink Jet Coder While there is some blurring of these lines, at Busch Machinery we define a small character inkjet coder as being capable of printing at least two lines of information in a selectable font size down to at least 1/16" height, or one line up to 12 mm height (0.47") and has the capability of printing at least some versions of barcodes. CIJ ink jet coders are the best for virtually any application, but cartridge systems can work well on porous and semi-porous surfaces for much lower cost. Large character ink jet coder A Large Character Ink Jet Coder is defined a capable of printing a single line from 12 mm height to nearly 4 inches high on a single print head (nearly 8" when doubled up). Beyond that there are two categories of large character inkjet printing: high resolution and low resolution. High Resolution Large Character Industrial Inkjet Printers With the improvement in inks and inkjet technology it is now possible to print on corrugated and other large surfaces with 300 dpi resolution in wide swaths of up to 4" high on a single printhead, and up to 8" with dual print heads. Furthermore inks are available that allow printing on virtually any surface. A great way to eliminate more expensive print and apply labeling systems with their higher initial and operating costs. Print text, graphics, and barcodes with 99.9% readability! High Resolution Large Character Industrial Inkjet Printers