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Copyright 2008 by Automatic Test & Control Limited. All rights reserved.
Form, Fill and Seal (FFS) Flexible Packaging
End Seal TechnologyDevelopment Project
Developing collaborative partnerships that optimise the business of product research and development,
assisting customers to exploit science and technologyto create value, profit and growth
Copyright 2008 by Automatic Test & Control Limited. All rights reserved.
Horizontal Form, Fill and Seal (HFFS) Flexible Packaging
Infeed Transports products
into folding box
Fin Seal Unit Forms longitudinal seal
on wrapper tube
Folding BoxForms wrapper tube
around products
End Seal UnitForms transverse seal on wrapper tube and cuts into separate packs
using technologies ranging from simple rotary motion to high
integrity box motion
Copyright 2008 by Automatic Test & Control Limited. All rights reserved.
Box Motion
Pros
Independent control of verticaland horizontal jaw motion allows wide range of product lengths and heights to be wrapped on same machine
Constant seal time provides high integrity (gas tight) seals over wide speed range
Misplace Product function operates when jaws are stationary as products are actively transferred over bottom jaw
Cons
Maximum speed limited (typically < 130ppm) by displacement and acceleration constraints in positioning crimp jaw mechanism
Existing HFFS End Seal Technologies
Rotary Motion
Pros
High machine speeds achieved(typically > 300ppm) by matching crimp radius to bag length and using 2 or more jaws per shaft
Cons
Fixed crimp centres dedicate machine to wrap a limited range of product lengths and heights
Cannot guarantee seal quality as seal time decreases with increasing machine speed
Misplaced product function can be unreliable since products are not actively driven over bottom jawwhen crimp shaft remains stationary
Copyright 2008 by Automatic Test & Control Limited. All rights reserved.
Vertical Form, Fill and Seal (VFFS) Flexible Packaging
Back Seal UnitForms longitudinal seal on wrapper tube
Forming Tube and ShoulderForms wrapper tube around products
End Seal UnitForms transverse seal on wrapper tube and cuts into separate packs using technologies ranging from simple intermittent motion to high integrity continuous (box) motion
InfeedProducts dropped from upstream equipment
Copyright 2008 by Automatic Test & Control Limited. All rights reserved.
Existing VFFS End Seal Technologies
Continuous Motion
Pros
Relatively short product dropheight prevents damage to products
High machine speeds possible(typically > 120ppm) usually limitedby effects of gravity when dropping products
Cons
Mechanically more complex - 1 axis to drive wrapping material and back seal unit, 2 axes to drive horizontal and vertical jaw motion
Intermittent Motion
Pros
Mechanically simple1 axis to drive wrapping material, end seal unit and back seal unit normally driven by pneumatics
Cons
Relatively large product drop height (set by maximum bag length) can cause damage to products
Maximum speed limited (typically < 80ppm) by sequential wrapper / jaw index motion
Copyright 2008 by Automatic Test & Control Limited. All rights reserved.
New End Seal Technology Research Process
INPUTPros and Cons
of existing HFFS and VFFS
end seal technology
OUTPUTNew technology that
includes majority of the pros while eliminating
most of the cons
Copyright 2008 by Automatic Test & Control Limited. All rights reserved.
New End Seal Technology
Features
High machine speeds possible, comparable with existing rotary motion technology
Wraps a wide range of product lengths and heights on same machine, comparable with existing box motion technology
Single axis version provides extended seal time compared to rotary motion technology
Twin axis version provides constant seal time over a wider speed range compared to box motion technology
Provides new functionality that is not available with existing technologies
Possible to retrofit single axis version to existing rotary machines with minimal modifications
Same technology can be used on both HFFS and VFFS applications
Constant Seal Time Specification
Bag Length 180 mm
Product Length 100 mm
Product Height 40 mm
Seal Time 100 ms
Maximum Packs Per Minute Rate
Existing Technology 130 ppm
New Technology 260 ppm
Copyright 2008 by Automatic Test & Control Limited. All rights reserved.
New End Seal Technology
Benefits
Machine User
Increase productivity in multi-line plants by having the ability to run full product range on each machine, transferring production between lines as required
Reduce training, maintenance and spares costs by reducing the number of machine variants within the plant
Access to niche markets by providing new functionality not available with existing technology e.g. high speed “Cut and Count”
Machine Manufacturer
Significantly reduce design, manufacturing and selling costs by building fewer machine variants which are capable of wrapping a wider range of products
Generate retro-fit business by upgrading existing rotary machines to utilise new technology
Existing End Seal TechnologyDifferent machine variants required, each only
capable of running a limited product range
New End Seal TechnologyPossible to use identical machines, each capable of running the full product range
Product Range
Line 1
Line 2
Line 3
Product Range
Line 1
Line 2
Line 3
Copyright 2008 by Automatic Test & Control Limited. All rights reserved.
Products such as chocolate biscuits are normally individually wrapped using a high speed primary wrapper before being collated into multi-packs on a secondary wrapper. The cut and count function could provide an alternative way for supermarkets to supply products in multi-packs using only a primary wrapper. The number of products chained together is variable, while the seals between products in the multi-pack are perforated allowing the products to be separated and individually opened.
Minimising Packaging using New End Seal Technology “Cut and Count”
Copyright 2008 by Automatic Test & Control Limited. All rights reserved.
2 x 6
3 x 4
3 x 4 stack
1 x 12
4 x 3
When large meat or cheese slice portions are supplied in pre-formed gas flushed plastic trays, the extended “use by” date is foreshortened to typically 2 or 3 days once the pack is opened. The cut and count function could provide an alternative way for supermarkets to supply the same product quantity divided into a programmable range of individual portion sizes. Each portion can be removed and opened while preserving the extended “use by” date of the remaining product. The chain of products can be easily folded to produce a stack, which can be held in place using, for example, adhesive labels folded over the stack edges .
Reducing Food Waste using New End Seal Technology “cut and count”
Copyright 2008 by Automatic Test & Control Limited. All rights reserved.
Other HFFS Development Projects
InfeedLow/zero pressure
inline feeding & storage
Fin Seal Unit Constant/Extended
seal time
Folding BoxDifferent pack styles
e.g. semi rigid
Reject Station Combines benefits of
flap and air blow-off
Copyright 2008 by Automatic Test & Control Limited. All rights reserved.
New End Seal Technology
For more Information
Please contact [email protected]
Telephone
+0044 (0)141 812 6031
Address
Automatic Test & Control Limited35 Lubnaig DriveLinburn EstateErskinePA8 6AU
