Flow Pack Machine FPC5: flexible, modular, high-performance
Each of the two packaging lines consists of an FPC5 for primary packaging, which is designed to process five different product formats. Both lines are directly linked to the moulding plant, and each has a downstream cartoner for secondary packaging. Both lines also offer the option of diverting small formats via a return flap. These formats are diverted into collection boxes and transported manually to vertical flow-wrapping machines, where they are packaged into multipacks as bulk goods. The second line which, unlike line 1, can handle not only primary but also secondary packaging if required, includes an additional FPC5, which was specially developed for processing triple multipacks using flow-wrap packaging. To this end, a transfer wheel was integrated to transfer the packaged chocolate bars from the first FPC5 to the second. Once the multipack has been formed, it is also fed directly into the cartoner.
© Theegarten-Pactec GmbH & Co. KG
Three applications, one solution – for maximum production diversity
Three main application scenarios were decisive in the design of the FPC5 to meet the chocolate manufacturer’s specific requirements. The Theegarten-Pactec machine demonstrates its outstanding performance and high flexibility in all three areas of application.
Primary Packaging Enabling Maximum Format Flexibility
As a practical solution for products that are not directly cartoned, the first scenario involves the ejection of small-format products via a return flap. These are packaged at a speed of 900 products per minute, gathered in collective containers (big bags) and manually fed to the vertical flow-wrapping machines for secondary packaging into pillow bags or stand-up pouches.
Secondary Packaging in Cartons
The second application scenario is ideal for formats with standard requirements. Here, chocolate bars are individually packaged into flow packs and then fed directly to the downstream cartoner. Long bars can be packaged at a speed of 500 products/min, for example, or small chocolate bars at 700 products/min.
Secondary Flow-Wrap Packaging with Carton Tertiary Packaging
In the third scenario, individually packaged bars are transferred via a transfer wheel at a 90° angle to a second FPC5, where they are grouped into packs of three and packaged into flow packs with the long side leading. The triple packs are then fed back to the cartoner via a belt behind the packaging machine, where the individual bars are otherwise secondary packaged into display cartons.
Multi-Format Solution
To achieve the exceptional flexibility of this unique and easy-to-use multi-format solution, Theegarten-Pactec opted for a combination of manual counter adjustment with target value specification. The required settings for each product format – such as the width and height of the belt guides, the position of the print mark sensor and the sealing unit – are stored as product recipes in the touch panel. When changing formats, the operator loads the desired format via the display. The new setpoints are then activated on the respective spindles. These initially switch to ‘red’ because the actual values still correspond to the previous format. The operator then manually adjusts each spindle to the displayed setpoint. As soon as this is reached, the spindle switches back to ‘green’. This visual feedback helps the operator carry out the changeover completely and correctly without the need for manual re-measurement. The deliberately chosen manual solution is not only more economical than fully automatic adjustment via motors, but also much more robust and requires less maintenance, which is especially advantageous given the frequent cleaning intervals required for format changes.
