Automatic tray sealer packaging machine

What is automatic seal vacuum machine?

Automatic seal vacuum packaging machines are using for vacuuming air around perishable products like foodstuffs such as pickles, red meat, chicken, fish and … for increasing their shelf life. Automatic machine can perform measuring procedures, filling, vacuum, seal and printing information automatically.

Operation of the machine

The operation of the machine is as follows:

• Pre-made trays are placed on the machine automatically or manually, and the product is loaded into them automatically or manually.
• Then the trays containing the product are guided into the machine’s mold and packaging is done normally or using the MAP (Modified Atmosphere Packaging) method (in this part, film is sealed onto the tray).
• After this part, the packaged trays can be directed to the jet printer (date printer) or label printer, and after completing the mentioned steps, they can finally accumulate on the turntable.

The automatic tray sealer machine is easily adjustable for different tray sizes to meet the needs of some manufacturers for packaging products. It is only necessary to have a mold for each tray shape so that they can place the relevant mold in the machine during packaging of their product in the desired tray, and after making the necessary adjustments, they can package their product.

The setup and settings of the machine can be easily done by the operator, as the machine is equipped with a very accurate control system and user-friendly software platform, which is both simple and professional. Continuous research on new technologies has helped us to skillfully introduce the automatic tray sealer machine to the market with advanced systems and user-friendly and reliable equipment.

Additional options of the machine

• Capability to install different fillers for granular, powdery, diluted liquids, concentrated liquids, and semi-solid heterogeneous products
• Capability to install devices to control and guide trays to the filler
• Capability to install a UV tunnel at the machine’s entrance to reduce microbial load on trays before filling
• Capability to install a weight control system (check weigher) to monitor product weight before packaging
• Capability to install a gas capsule for more accurate control of gas in packaging using the MAP method
• Capability to install a remote maintenance system for easier customer support
• Capability to install packaging with printed film
• Capability to install a rower at the machine’s output to convert trays into a single row and pass them under the jet printer and labeler
• Capability to install a rotating table for accumulating trays at the end point of the machine
• Capability to install options for creating packaging beauty
• Other options can be performed according to customer consideration. For more information, please contact our experts.

Different parts of the automatic seal vacuum machine 

Touch control panel of the machine

• 7-inch high-quality touch screen display from the reputable and high-quality Delta brand
• Machine control system: PLC with a color control panel with by languages, Persian and English
• Control settings of temperature, vacuum percentage, gas injection, pressure, speed, and many other parameters are easily done through the touch screen.
• User-friendly and simple but professional interface.

Gold Automation by the capability of repairing the machine remotely (Remote maintenance)

Gold automation is like a complete computer (PC) on the machine and helps after sale services department of this company to solve the problems online, in a way that part of problems will solve by the company with the usage of internet.

The use of the Gold Automation option in the automatic tray sealer machine will have the following advantages:

• Remote communication with the machine via the internet for troubleshooting (from anywhere in the country)
• A very professional program with high-quality graphics for quick and easy machine settings
• A user-friendly interface
• Equipped with a powerful processor for running heavier programs
• Perfect for automatic machines with various options.

Easy cleaning

he engineers at Packen have designed the automatic tray sealer in such a way that it is easily accessible from all points, making daily cleaning easy.

• The frame material and chain drive system of the machine are made of 304 stainless steel to prevent corrosion during cleaning.
• The filler has 2 professional washing programs to ensure that no residue is left inside and does not cause contamination over time.

Electrical panel of the machine

The electrical panel is designed in a completely professional manner and contains high-quality electrical components from reputable brands. Some of these components include:

• PLC (Programmable Logic Controller) from Siemens
• HMI (Human-Machine Interface) from Delta
• Temperature card from Delta
• PLC relays from Phoenix
• Pressure terminals from Raad (resistant to vibration and loosening)
• Contactor and thermal switches from Muller or Siemens Germany
• Power supply and phase control from high-quality Emren brand
• SSR (Solid State Relay) from high-quality Autonics brand
• Use of very high-quality parts in other electrical parts of the machine

The electrical panel of the automatic tray sealer is also placed in a way that makes its availability very easy. The appropriate design in this section has made repair and maintenance of the machine and inspect of the electrical panel easier.

Mold of the machine

Some features of the mold of this machine include:

• One-piece cast and machined mold that enables error-free modified atmosphere packaging.
• The mold has very high waterproofing.
• The silicone bands placed on the mold parts are well designed and selected in various types and good quality, and are located completely standard and principled in their place.
• The machine’s base plate has a unique design.
• It has high-quality 304 stainless steel pins and phosphor bronze bushes for smooth movement and proper insertion of the pins into the bushes (a very important factor that demonstrates its quality in the long term).
• Each seal mold has separate elements.
• Each seal mold has a separate thermocouple for temperature control.
• The blades have a separate system, the tooth profile is well calculated and made, and they are also placed on the mold in a way that the mold temperature does not have a direct impact on them and does not heat them up.
• A very good channel is designed on the mold to accommodate all wires inside it and prevent the wires from getting in the way of the movement of other parts inside the mold. This makes repairs and maintenance easier.
• With the high knowledge and experience of Packen in mold design, we can offer more molds to our valued customers.
• The ability to work on various trays with different shapes is possible without limitation.
• It is possible to coat the aluminum parts of the machine in the case of your request.
• The machine mold can be changed in the shortest possible time (maximum 10 minutes).

High-quality chain with precise movement system

The chain rail is made of HP 1000 polymer, which has extremely high resistance to corrosion. This chain is designed and made in a U shape to maintain the chain’s movement properly in its path. This has several advantages for customers:

• Less noise: The chain has no extra movement and most importantly, it does not produce any extra noise.
• High precision movement: Most importantly, if the chain moves without any extra movement and properly in its path, the machine’s precision will increase, and the trays will be guided more accurately on the machine.
• Proper performance of tray moving rods: The tray moving rods are made of high diameter stainless steel, which are resistant to potential bending. This is important because if the rods are damaged, the transfer of trays into the mold will be done by error.

Output conveyor

Outlet conveyor is placed in the end of tray sealer packaging machine. This option caused to transfer the products without any error and extra movement after packaging to next part or next machine.

The frame of the machine

1. Some of the benefits of the body of the tray sealer machine in company are:
2. Strong and firm structure
3. Use of high thickness sheets
4. Low vibration
5. Resistant to accuracy loss over time
6. Completely 304 stainless steel material, shiny and corrosion-resistant with high beauty, resistant to corrosion and color change due to contact with food and cleaning materials
7. In this type of stainless steel (shiny corrosion-resistant stainless steel), less contamination remains on the surface and is easier to clean.
8. Designed according to international standards with technical and engineering principles.

Photocell

In the right side of the automatic tray sealer machine, a Photocell is placed for packaging food products with printed films, which can be adjusted in its correct position by some parts and has a much lower error rate for determining the correct film position. Unique design, very easy adjustment capability, high-quality sensor, desired number of rollers, and accuracy of film movement in the correct path are among the high advantages of this part.

Tighten the film

The advanced sensor of film by intelligent design ensures that the film is perfectly smooth before and after the mold, resulting in more accurate packaging. In this way, the film is sealed onto the tray more beautiful, and packaging is done without default. This part directly contributes to beautiful, wrinkle-free packaging without any problem.

The location of the film roll

Our unique design in this part ensures that the roll is properly placed and can be used at different widths if needed. This part is designed in a way to be easily and quickly adjustable. The film is placed on an air shaft with locking lugs and can securely hold the film roll and prevent any extra movement.

Changing the roll in Packen machines is very simple and can be done in the fastest possible way.

High-quality keys with a reliable brand

• High-quality keys from German brands such as Muller and Siemens, along with special silicone coatings
• High safety during operator usage of the machine and suitable washing capability.

Strong automation

This company has a powerful technical and engineering team for programming and automation of automatic tray sealer machines. This team is continuously working on improving the quality of machine programs and always attempts to provide programs without error.

Our goal in developing this group is to increase the quality, level of technology, accuracy of sensors, and parts of precised tools in our products.

Usage of PID system for controlling the temperature of the machine

• Usage of qualified and premium Siemens parts
• Equipped with a PID system for accurate temperature control, resulting in uniform and proper sealing (without deformation or weak sealing during packaging)
• Presence of 4 separate thermocouples for each mold, for packaging by more accuracy and separate control of the temperature of the molds from each other
• Packaging all trays in a uniform and correct manner.

High security system

The high safety of the automatic tray sealer machine prevents potential hazards for the operator. Number of the functions which were done to increase safety include:

1. The presence of four emergency stop buttons in different parts of the machine for shut down the machine quickly in case of an emergency situation.
2. The presence of an automatic chain locking system with a good safety factor to prevent operator injury.
3. Torque control by the machine’s drive due to accurate automation and programming of the machine.
4. The presence of a tower light to display the machine’s status.
5. The absence of sharp and dangerous edges on the machine.
6. The use of intelligent design and correct placement of different parts.
7. The use of suitable and high-quality materials in various parts.

Vacuum pump

The tray sealer machine of this company is equipped with a powerful vacuum pump and suitable valves for controlling the vacuum process properly. The volume of pump’s suction is 63 cubic meters, which increases the number of machine cycles per minute, allowing for more accurate and faster packaging of products using the MAP method. The speed of the tray sealer machines in Packen by modified atmosphere packaging (MAP) is high.

Powerful pneumatic system

The pneumatic system of the automatic tray sealer machine of this company is very powerful, calculated, and designed.

1. The maintenance of machine has a large size equal to 1.2 inch to prevent any loss in compressed air.
2. The main lower jack of the machine has been selected by a diameter of 160, which is very powerful and without any loss.
3. Due to the large size of the jacks, the valves also have a large size to control the jacks in the best possible way too.
4. The fittings of the machine have been selected from the very famous and high-quality brand CDC.
5. Large diameter of pneumatic hoses have been selected to be compatible with the sizes of the valves and jacks.
6. The pneumatic circuit of the machine has accurate technical and engineering calculations, which high quality and correct performance of the machine have been considered in its design.
7. The use of angle valve valves in quick setting and accurate vacuum path.

The main electromotor of the machine

Electromtors from the Iranian Electrogen brand and gearboxes have been selected with high quality to have a long life and to produce accurate movements in the machine with high precision.

Bearing system

The bearing system is without error and has qualified parts and plated and metal sprocket (ST37).

1. The chain rails of this company are in a U shape, which causes the chain moving in its correct way.
2. The sprockets have accurate and standard design.
3. The sprockets have gearbox for smooth operation.
4. The ball bearing inside the sprockets are selected from a qualified Japanese brand to have a long lifespan.
5. The sprockets have a large diameter to have more contact with the chain and therefore guide the chain more accurately.

The advantages of automatic tray sealer (seal vacuum) machine of Packen

• Sanitary design
• Strong sealing
• Easy and immediate cleaning
• Strong and solid structure and body
• Easy to use and user-friendly
• Low maintenance cost and easy repairs
• Multi-purpose application for different trays and products

Types of technologies for packaging of machine

Considering the great variety that exists among food products, for example: storage temperatures, microbial flora and different respiration rates, etc., the packaging technology of each product must be carefully selected.

Modified atmosphere method

The modified atmosphere technology of automatic seal vacuum (tray sealer) machines can increase the shelf life and quality of the product by changing the natural air composition inside the packaging. In this technology, the percentage of O2, CO2, and N2 gases is adjusted according to the composition of the food material in the packaging, so that the shelf life of the product increases significantly.

This technology is used in the manufactured machines of the Knowledge-Based Packen Company in a completely professional manner and is one of the most important features of the packaging machines of this company.

The procedure of this technology is as follows: a part of the air inside the tray that has reached the mold of the machine is sent out (vacuum), then a gas suitable for the product is injected into the tray, and ultimately, the film is sealed on the tray so that the modified atmosphere inside the tray remains. The combination of this method, which is vacuum and gas injection (MAP), is the most important technology used in automatic tray sealer machines.

Equilibrium modified atmosphere packaging

This packaging operates by controlling of the product’s respiration rate inside the package (EMAP technology). Oxygen is supplied to the package through micrometer-sized holes, and excess carbon dioxide is sent out. Eventually, this method can significantly increase the shelf life of products such as fruits, vegetables, and salads.

Natural atmosphere method

In this type of packaging, the product is secure only toward physical contacts and mechanical effects.

Vacuum method

Vacuum Packaging is one of the common methods. After being placed inside the tray, the product is packed by a vacuum that causes the atmosphere to send out of it.

All types of packaging methods by automatic tray sealer machine

Inside cut method

Inside-cut packaging makes the film have no borders around the tray and the beauty of the packaging increases significantly.

Packen is the only company in the country that can provide customers an automatic tray sealer packaging machine by capability of packaging using inside cut method.

Outside cut method

Outside cut pack is the most common type of packing. In this case, the film is cut at a distance of 2 to 2.5 mm from around the tray and then it is sealed on the packaging tray.

Easy peel point pack

This type of packaging is used for products that requires the film to be easily peeled off the tray during consumption. Therefore, the tab created by this method can greatly makes this task easier.

Hard open method

This type of packaging is used for products which film should not open during consumption (specially products which should export or send to other cities, in other words packages should place on each other for a long time).

In-Mold Labeling Method

Packaging food products using the in-mold labeling (IML) method can create a unique beauty. IML trays have labels molded into them during manufacturing. These trays have narrow edges, so their packaging must have special technology.

Vacuum Packaging

The vacuum packaging method is one of the common methods. After the product is placed inside the tray, it is packaged by vacuuming (sending out) the atmosphere from inside of the package.

Skirt out Packaging

This method (Skirt out pack) is used for cup trays. After packaging, the film is placed in a skirt shape around the tray.

Combination Packaging: inside cut peel point

This packaging method is a combination of the Peel Point and Inside Cut methods. In this method, the film is cut inside the edge of the tray and then a tab is created next to it to make it easier for the consumer to peel the film of the tray.

Bucket Packaging

Products which need to be placed inside a bucket are packaged using this method (Bucket pack). Usually, buckets have a high height.

Cup pack packaging

Packaging of cup trays by outside cut is done by this method.

Skin Pack packaging

Skin Pack packaging is one of the most attractive packaging methods in the industry. In this method, the product is vacuum-sealed to reduce biochemical degradation due to sending the air from inside of package. After packaging, the product is securely placed in its position and all surfaces of the product are covered with a film.

Different types of skin packaging by considering the shape:

• Skin packaging for products which will have a flat surface when placing on the tray or be no more than 2 cm out of the surface of the tray.
• Skin Pack packaging for products that will be about 4 cm above the surface of the tray after being placed inside it.
• Skin Pack packaging for products that will be up to about 8 cm above the surface of the tray after being placed inside it.

Hanging Pack packaging

One of the packaging methods for improving product sales is Hanging Pack packaging. After packaging, the trays are hung on store shelves for better showing to customer.

Smooth Cutting Edge packaging

For packaging trays with very narrow cut width, the Smooth Cutting Edge packaging method can be used.

Applications of full automatically tray sealer (seal vacuum) machine

The automatic tray sealer machine is used to package food products in plastic and aluminum trays. In this machine, loading the trays into the mold and moving out the packaged trays from the machine is done automatically and completely easy. In addition, this machine can be equipped with an automatic denester and filler.

Products which can be packaged by automatic tray sealer machine

• Pickles (such as pickled cucumber, olives). MAP method is used to preserve the freshness of the products in pickles and prevent softening of product and molding.
• Meals (such as Olivier salad, macaroni). MAP method causes preserving the minerals and vitamins in ready-to-eat and semi-prepared foods and prevents bad taste in food products.
• Dairy products. MAP method helps to preserve the main properties of dairy products (calcium, etc.) and prevents changes in color and taste, delaying spoilage.
• Various nuts, dried fruits, and dates. MAP method prevents the growth of insects and larvae in dried products, increases crispness and shelf life and prevents their rancidity.
• Bakery and confectionery products. MAP method prevents moisture loss in the products. This method helps preserving the odor and taste of the products for a longer period and also prevents mold formation in these products.
• Medical and pharmaceutical products. We provide completely hygienic packaging with suitable and sterile materials by the customer’s desired method for medical and pharmaceutical products.
• Various fresh fruits. MAP method is used to balance and preserve the respiration rate, freshness of fruits and preserves their organoleptic properties for a longer time.
• Vegetables, greens, and salads. MAP method preserves the color of grains in vegetables, greens, and salads and prevents wilting.
• Various seafood products (such as shrimp, fish). MAP method preserves the freshness, odor, and taste of seafood products and prevents oxidation and spoilage in these products.
• Red meat from livestock. MAP method preserves the red pigments of meat, freshness, and also prevents oxidation of hemoglobin and myoglobin in livestock and meat.
• Poultry. MAP method preserves the color and texture of poultry meat and prevents spoilage reactions and undesirable odors in these products.
• Processed meals (sausages, salami; nuggets, hamburgers). MAP method preserves the freshness of the product and prevents quality loss and potential spoilage in packaging.

Accessories which can be used in production line

Automatic denester

In this machine, it is not needed to use operator, and opening the trays from each other and loading them onto the machine is done automatically and continuously. The great advantage of this machine is the fast change of its mold for trays with different sizes. Also, its accuracy in separating the trays from each other without errors is one of its superior features.

Advantages of automatic denester:

The technical standards observed to in this machine ensure the following benefits during its usage (product packaging), provide these achievements for manufacturers.

• The machine is designed in a way that it can be easily cleaned.
• It has a highly hygienic system.
• Easy settings and very convenient control.
• Very low compressed air requirement.
• Capability to work with a servo motor.
• Suitable dimensions for space saving.
• Capability to be installed on various systems.
• Maximum speed of handling up to 60 dishes per minute.
• Simple and very user-friendly.
• Strong body made of corrosion-resistant stainless steel 304

UV Tunnel

UV tunnel is a fast, chemical-free, cost-effective, and environmentally friendly method which purifies surfaces from harmful bacteria, viruses, fungi, and yeasts.

UV tunnels are ideal for sterilizing surfaces. This machine is used in the food industry to sterilize trays. Removing microorganisms from trays and reducing microbial load has a direct impact on increasing the shelf life of food products. UV tunnels can be installed at the entrance of automatic machine before filler.

Converter of single to multiple row and vice versa

The single-to-multiple row converter machine is responsible for consolidating multiple rows into one row or separating one row into multiple rows.

Technical Specifications:

• Utilization of high-quality electrical and electronic parts for easy and convenient use of the machine.
• Use of qualified electromotors and gearboxes for error-free and long-term operation of the machine.
• Usage of accurate motion systems for smooth machine operation.
• Stainless steel structure and body with corrosion-resistant material to potential corrosion, oxidation, and damage.

Observing the product: Single to Multiple Row Converter and Vice Versa.

Fillers

• Fillers can be in the following forms:
• Filler for granulated products
• Filler for powdered products
• Filler for diluted liquids
• Filler for concentrated liquids and heterogeneous semi-solid products

When products are in the form of diluted liquids, concentrated liquids, heterogeneous semi-solid materials, or granulated solid products, filling the product into trays can be done automatically and continuously by these machines, eliminating the need for labor and preventing contamination, are among the most important advantages of using these machines. Additionally, with settings on the machine, the amount of product that needs to be filled into the trays can be controlled and then packaged easily.

• Filler for concentrated liquids. This machine is used for food products such as honey, jam, olivier salad, sesame cream, breakfast chocolate, and date syrup. It can be equipped with a heater and mixer in its tank to prevent clogging in the connections for products which may change viscosity and becoming solid during filling.

Viewing the product: Filler for concentrated liquids.

• Diluted liquid filler. This machine is used to fill various thin liquids in different trays, such as mineral water, yogurt, flavored drinks, and products with viscosities close to water. The diluted liquid filling machine, also known as a gravity filler, operates without a pump or motor and is based on the gravitational force of the product.

Viewing the product: Diluted liquid filler

• Volumetric filling machine. The volumetric filler is used for filling various products that cannot be filled into trays by a weighing filler due to their shape and texture. In these cases, this filler is used. Products which can be filled into trays by this filler include processed olives and fruit salad.

Viewing the product: Volumetric filling machine

• Multi-Head weigher. This type of filler is used for granulated products such as dry fruits, nuts, legumes, grains, vegetables, nuggets, falafel, and small pieces of chicken or red meat are among the items that can be filled into trays using this method. In general, this machine is usable for any substance where its precise weight is crucial in packaging,
• This type of filler is one of the most accurate and widely used machines among fillers which utilizes a highly accurate weighing mechanism. This type of machine is equipped with very accurate and sensitive scales that weigh the product with the least of weight tolerance.

Viewing the product: Multi-Head weigher

Automatic rower

The automatic rower is placed at the output of the automatic machine after the outlet conveyor belt and put the trays in rows. In the next step, a jet printer or labeler can be installed. The jet printer can imprint the date, price, and production specifications on the tray, and the labeler has the ability to stick labels on packaged trays. These are characteristics of this machine: washable and hygienic standards.

Viewing the product: Automatic row aligner

Automatic lid placer

It is adjustable for different shapes of lids and can be installed at the output of the machine to place lids on trays automatically, eliminating microbial load when placing lids on them manually.

Viewing the product: Automatic lid placer

Traffic table (rotary table)

The rotary table is placed at the end of the packaging line for gathering packaged trays. The table is made of high-quality and washable 304 stainless steel.

Viewing the product: Traffic table (rotary table)

Metal detector

The application of metal detectors is to detect metals inside any product, such as pharmaceuticals and food products. There is always the possibility of accidental existence of metal contamination in products, and in such cases, metal detectors are used as a control system. Therefore, metal detectors play a very important role in the quality control system of packaged products.

Viewing the product: Metal detector

Check weigher systems

Check weighers are used to control the weight of products. If the weight is less or more than your desired amount, the package will be automatically removed from the line. These machines are placed at the input and output of the tray sealer (seal vacuum) machine. They also have the capability to calculate the price of the product based on its weight automatically and transfer the data to a jet printer for instant price imprinting on the packaging.

Viewing the product: Check weigher systems

Designing packaging lines using tray sealer machines according to customer space

Packen Company can design packaging lines according to standards and the requirements of customers. This task is done by the competent and experienced engineers and experts of this company with the aim of meeting the requirements of customers.