Semi-Automatic tray sealer Machine

Introduction to Different Parts of the Machine

Touch Control Panel

• A high-quality 10-inch touchscreen display from the reputable Delta brand.
• Control settings for various parameters such as temperature, vacuum percentage, gas injection, ejector system, stepper motor, pressure, and more are managed through the touchscreen.
• It supports two languages: English and Persian.

Film Waste Collection System (Stepper Motor)

Use of High-Precision Stepper Motor with Drive:

• Ensures high accuracy in collecting film waste (as the stepper motor offers much greater precision compared to an electric motor).
• Adjustable Power and Speed for Film Waste Collection, providing the following valuable benefits:
  1. Ability to collect films made of aluminum, metallized materials, and polymer films with varying thicknesses.
  2. Adjustable pulling force for different film materials and thicknesses.
  3. Adjustable speed to prevent film tearing and wrinkling during product packaging.
• High IP Rating, resistant to dust and moisture penetration into the machine.
• Features high Newtonian power and durability, ensuring the film does not get stuck or tear.
• Significant Reduction in Film Waste.

Machine Mold System

• One-Piece Cast Shell:
  The machine features a high-precision, high-quality, and durable one-piece cast shell that has been meticulously machined.
• Highly Sealed Mold Shell:
  The mold shell ensures excellent sealing performance.
• Silicone Strips on Mold Parts:
  The silicone strips placed on the mold components are well-designed, selected in excellent quality and varieties, and positioned in a way that ensures they stay perfectly in place according to standard specifications.
• Unique Base Plate Design:
  The machine features a uniquely designed base plate for optimal functionality.
• 304 Stainless Steel Pins and High-Quality Phosphor Bronze Bushings:
  These ensure smooth and accurate movement of pins within the bushings, contributing to the machine’s reliability.
• Separate Heating Elements for Sealing Molds:
  The sealing molds are equipped with separate heating elements.
• Separate Thermocouple for Mold Temperature Control:
  Each mold is monitored with its own thermocouple for precise temperature control.
• Independent Blade Systems:
  The blades are independently designed with precisely calculated profiles to avoid heat damage and to ensure they maintain optimal conditions. They are positioned on the mold in a way that prevents the mold’s temperature from affecting them.
• Channels for Wiring Inside the Mold Shell:
  Two channels are integrated into the mold shell, where all wires are housed, ensuring they do not interfere with other moving parts. This design also simplifies maintenance and repairs.
• Custom Mold Design Expertise:
  Thanks to Steel Gharb Asia’s technical expertise in mold design, the company can provide molds with a higher number of cavities to meet customer needs.
• Flexibility in Custom Mold Shapes and Sizes:
  The company has the ability to design molds in a wide range of shapes and dimensions, with no limitations in this area.
• Quick Mold Replacement:
  The mold can be replaced in less than 10 minutes.

Machine Body

The machine body is made of high-quality 304L stainless steel. The brushed and polished steel finish enhances the machine’s aesthetic appeal. The advantages of this design include:

• High-Quality Stainless Steel: Resistant to corrosion and any potential discoloration caused by contact with food and cleaning materials.
• Stunning and Unique Aesthetic: The appearance of the machine is both attractive and distinctive.
• Reduced Dirt Retention and Easy Cleaning: The brushed polished steel retains much less dirt and is easier to clean.
• Durable and Robust Body: The all-steel body ensures that the machine’s accuracy and performance remain intact over time.
• Thick Stainless Steel Sheets: High thickness of the stainless steel sheets used contributes to durability.
• Designed According to International Standards: The design adheres to technical and engineering standards.
• Smooth Wheels: The machine is equipped with smooth wheels for easier mobility and transfer.

Machine Table

The machine table is rotational and is made from high-quality, one-piece cast aluminum alloy.

• High Sealing Performance: Ensures a very high level of sealing for packaging products using the Modified Atmosphere Packaging (MAP) method, providing accurate and reliable results.
• Unique Shape and Aesthetic: The design is both functional and visually appealing.
• Engineered Design: Designed with adherence to engineering principles and necessary standards.
• Easy and Hygienic Cleaning: The table is easy to clean, ensuring proper hygiene.
• Prevents Food Residue Accumulation: The design prevents food buildup in corners, reducing the risk of bacterial contamination.
• Durable Coating: Optional coating to enhance the machine’s longevity and prevent discoloration from contact with food and cleaning materials.

Electrical Panel of the Machine

Steel Gharb Asia has made efforts to use the best and highest quality components in the electrical unit of the rotary table vacuum sealing machine. Some of the components used include:

• High-Quality PLC: From Siemens brand.
• HMI: From Delta brand.
• Temperature Card: From Delta brand.
• PLC Relays: From Phoenix brand.
• Terminals: Rade brand, pressure type (resistant to vibration and loosening).
• Contactors and Thermal Switches: From German brands such as Moeller or Siemens.
• Power Supply and Phase Control: From the high-quality Omron brand.
• SSR Relays: Premium quality, from the Autonics brand.
• Other Components: From top-tier brands available in the market.
• The electrical panel is conveniently located at the back of the machine for easy access.

Vacuum Pump of the Machine

The vacuum pump of the machine has a capacity of 40 cubic meters and is from the high-quality Posh Iranian brand.

Machine Tray

The dimensions of the machine tray are 44 x 34 cm. Thanks to the company’s advanced expertise in mold design, you can use molds with more cavities to increase the packaging speed.

PID System

The features of the PID system for controlling the machine’s temperature include:

• High-Quality PID Controller: Made from the premium Delta brand.
• Precise Temperature Control: Ensures uniform and accurate sealing during packaging (without deformation or weak seals).
• Up to 4 Separate Thermocouples: One for each mold, providing greater accuracy during the packaging process and allowing for independent temperature control of each mold.

Film Guide Rollers

One of the key features of the machine is the use of additional rollers for guiding the film:

• This machine uses 4 idle rollers to properly guide the film, ensuring it moves without wrinkles and is correctly aligned, preventing early tearing of the film during packaging.
• All rollers are equipped with ball bearings for smooth operation.
• The rollers feature adjustable bases and conical-shaped components to significantly assist in guiding the film along the correct path.

Machine Push Buttons and Switches

The machine is equipped with high-quality push buttons and switches:

• The push buttons and switches are from the Moeller brand (Germany) and come with special silicone covers from the same brand.
• Operators benefit from high safety when using the machine.
• High washability for easy cleaning.
• The machine is equipped with a high-quality Emergency (Emergency) button from Moeller, offering long lifespan and high safety.
• The main switch is from the Siemens brand, providing a high safety factor.

Film Roll Brake System

The machine utilizes a thoughtfully designed and precise braking system to control the unwinding of the film from the roll:

• It features two film-holding rollers with a professional bearing system specifically designed to control the unwinding of the film from the roll and guide it accurately.
• The machine is equipped with a professional brake system that is easy to adjust, allowing for precise control of the tension (tightness or looseness) of the film unwinding, according to its material type.

Inspection Windows

The machine is equipped with four inspection windows, making maintenance and repair tasks easier.

Polyethylene Film Sensor System

The polyethylene film sensor system for printed films on the machine is easily adjustable. This part of the design is highly intelligent.

• Located on the left side of the machine, components are designed to allow easy adjustment of the sensor to its correct position, resulting in a very low error rate when detecting the film’s correct position.

Key features of this system include:

• Unique design.
• Very easy adjustability.
• High-quality sensor.
• A large number of rollers positioned for optimal film movement.
• Accurate guidance of the film in the correct path.

Use of Angle Valve Fittings for Fast and Accurate Vacuum Path Adjustment

The angle valve fittings are pneumatically controlled, providing high power and speed for opening and closing the vacuum paths. In total, four valves are responsible for opening and closing the vacuum outputs.

Use of Precise Transmitter Sensor for Vacuum Pressure Control

The use of a high-precision pressure transmitter sensor, from reputable brands, ensures accurate control of the vacuum level inside the mold. This sensor plays a crucial role in ensuring the precise execution of packaging using the MAP method in the company’s machines. The sensor reads the pressure value and sends it to the PLC for further processing.

Advantages of the Machine

The technical standards used in this machine provide numerous advantages for the manufacturer when packaging products:

• High-Quality Electronics: Components from reputable and high-quality brands.
• Durable Electric Motors and Gearboxes: Ensures long-term, error-free operation of the machine.
• Powerful Pneumatic System: Ensures error-free packaging (accurate MAP method execution – strong and flawless sealing).
• Precision Components: Ensures accurate placement of the table in its correct position.
• High-Precision Parts: Ensures the film is properly positioned on the container and provides a strong, clean seal and cut.
• Quality Parts and Precise Motion Systems: Ensures smooth and error-free operation of the machine.
• Stainless Steel Connections: Prevents oxidation and potential damage.
• Corrosion-Resistant Stainless Steel Structure and Body: Ensures durability.
• Ergonomic and Practical Design: Facilitates easy cleaning and prevents damage to parts.
• Compact Size and Affordable Price: Suitable for medium packaging capacities.
• Simple Design with High Efficiency: Easy to use and operate.
• Strong Technical Support: Reliable customer service.
• Quick Mold Change: Less than 10 minutes for mold replacement.
• Low Maintenance: Easy to maintain due to the standard design.
• Accurate Film Feed System: Ensures the film moves precisely in the correct path.
• Precise Temperature Control and Adjustable Sealing Pressure: Ensures optimal sealing.
• Smooth Rollers and Sufficient Quantity: Ensures proper film transfer.
• Rotary Table and One-Piece Mold Casing: Cast and machined for high performance and unique aesthetics.
• Easy Device Setup: Configurations are accessible via the touch display (PLC).
• Automatic Operation: Strong automation system.
• Approved by Food Industry Organizations: Due to its hygienic design and full washability.
• Safety-First Design: Meets necessary safety standards for user operation.

Types of Packaging Technologies

• Modified Atmosphere Packaging (MAP)
  MAP packaging method adjusts the air inside the package by replacing it with a specific gas mixture, which helps preserve the shape, color, and freshness of the product for a longer period. Typically, gases like carbon dioxide, nitrogen, and oxygen are used to modify the atmosphere inside the package.
• Controlled Modified Atmosphere Packaging (EMAP)
  This method controls the product’s respiration rate inside the package by using micrometric holes to allow oxygen in and expel excess carbon dioxide. EMAP can extend the shelf life of products such as fruits, vegetables, and salads.
• Natural Atmosphere Packaging
  This method uses natural atmospheric conditions to package products. In this case, the product is protected only from physical contact and mechanical influences but does not have any special gas modification.

Types of Packaging Methods Used by This Device

• External Cut Method:
  The most common packaging method, in which the film is cut 2 to 2.5 mm away from the edge of the container and then sealed over the container’s opening.
• Easy Peel Point Pack:
  This method is used for products that need the film to be easily removed from the container’s opening during consumption. The tab created by this method helps make the process of removing the film easier.
• In-Mold Labeling (IML):
  In this method, packaging food products in IML containers creates a unique aesthetic. IML containers are labeled during production, and they have narrow edges, which require a specific technology for packaging.
• Vacuum Packaging:
  A common packaging method, where the product is placed inside a container, and the air is vacuumed out to create a sealed package.
• Skirt All Pack:
  In this method, after packaging, the film forms a skirt around the container.
• Combination Packaging:
  This method combines the Peel Point and Inside Cut methods. The film is cut closer to the container’s edge, and a tab is created next to it to help consumers easily peel the film off the container.
• Bucket Pack:
  For products that need to be packaged in a bucket, this method is used. Buckets are typically tall in height.
• Cup Pack:
  This method is used for packaging round-mouth containers.

Application

The semi-automatic vacuum sealing machine is designed for workshops and factories with medium-scale production. Its key features include compact dimensions and ease of use.

This device is also used in large manufacturing plants where the goal is to package products on a medium scale for initial tests and market evaluation. After necessary testing and trials, they determine how to scale up production for higher capacities.

Packable Materials Using the Machine:

• Pickles and Olives: MAP method is used to preserve the freshness and balance of brine in pickled products like cucumbers and olives.
• Ready-to-eat and Semi-prepared Foods (e.g., salad olivier, stews): The MAP method helps retain the minerals and vitamins in ready-to-eat and semi-prepared foods, preventing off-flavors.
• Dairy Products: MAP preserves the essential properties of dairy products, prevents changes in color, taste, and aroma, and delays spoilage.
• Nuts, Dried Fruits, and Dates: MAP prevents insect infestations and larvae in dry food products and increases their crispness and shelf life. It also prevents oiling in nuts
• when packaged properly.
• Bread and Pastries: MAP helps preserve moisture, aroma, and flavor in baked goods, preventing mold formation and retaining freshness.
• Medical and Pharmaceutical Items: We offer hygienic and sterile packaging of medical and pharmaceutical products according to the customer’s desired method.
• Fresh Fruits: MAP maintains the balance of respiration rate, freshness, and overall appearance of fruits while extending their organoleptic properties.
• Vegetables, Fruits, and Salads: MAP preserves the pigments in vegetables, fruits, and salads, preventing wilting and shrinkage.
• Seafood Products (e.g., shrimp, fish): MAP keeps the freshness, aroma, flavor, and taste of seafood intact, while preventing oxidation and spoilage.
• Red Meat and Offals: MAP preserves the freshness and red pigments of meat and prevents oxidation of hemoglobin and myoglobin.
• Poultry and Other Birds: MAP helps maintain the color, texture, and tenderness of poultry meat, preventing reactions that cause spoilage or undesirable odors.
• Processed and Semi-processed Meat Products (e.g., sausages, cold cuts, nuggets, hamburgers): MAP preserves the freshness of processed meats and prevents quality degradation and spoilage.