Eco friendly box closing machines

Opitz range of box erecting and case closing machines apply recyclable gummed paper tape instead of self adhesive tape. Their volume reducing box closers offer dispatch operations a faster and more sustainable return on investment . They eliminate plastic from the package.

Going Green – Sustainable solutions that make the case without plastic

Opitz Specialise in eco friendly box closing machines and case erectors that apply gummed paper tape as an alternative to Self adhesive plastic tape.

Eco Friendly Box Closing machines use gummed tape

Gummed paper tape consists of a kraft paper coated with an natural glue layer which, once wet, adheres to the cardboard box. It’s works like licking the envelope.

Gummed tape has several advantages over self adhesive tape, these include environmental, consumer and transportation benefits:

  • Fully Recyclable
    Reducing plastic waste has been a hot topic recently. The problem with plastic tape is that it contaminates the waste stream. In contrast gummed tape consists of recyclable materials: the carrier material is made of wood and the glue is based on renewable resources like potatoes and maize. This means that the whole box will break down when composted or can be recycled.Logo-Recycle
  • Tamper-evident closure
    Because gummed tape is the same type of material as the corrugated case it is sticking too the tape cannot be removed without tearing the box or cutting the tape. This makes it an ideal tamper evident solution. The result is a closure that is accepted for known consignor shipments as well as air freight.
  • Dust protection
    Gummed tape makes a homogenous bond with the cardboard resulting in a better seal. Because the tape is wet, gummed tape bonds well to the often dusty surface of the cases. Dust is sometimes a problem for self adhesive tape which looses its adhesive properties when coated in dust. The superior seal has benefits in the packaging of pharmaceuticals. This protects the contents against dust. Opitz also offers cross seals to fully seal the case.
Case sealing options
Case sealing options
  • Improved Stability & durability
    Gummed tape closures are more stable than self-adhesive tape closures. This is particularly important when packages are heavy. In drop tests gummed paper tape closures handle better in falls. Gummer tape is more durable when temperature and humidity varies, crucial for air freight. Gummed tape can be strengthen with fibres to make it even stronger.
  • Knife Free opening option
    The addition of a tear strip makes it possible to open the case without the need for a knife.Knife free case opening system

Gummed Tape Volume Reducing Case Closers – Removing the Fillings

The Opitz Volume reducers removes the need to fill cases with air cushions or loose fill removing another source of plastic waste from the package and ultimately the environment.

The prize winning  Vario 558 measures the height of the contents of the box and cuts the flaps down effectively reducing the height of the box. Reducing the height reduces the need to back fill with air pillows or other loose fill materials. Because the Vario 558 can handle cases of different footprints and heights one machine can cover a range of product sizes simultaneously. This makes it the ideal machine for varied and smaller volumes of cases.

Fast Return of Investment

As well as doing their bit to save the planet, customers in the electronics and clothing industries run the GO588  volume reducing box closer because of the fast return on investment. The box closer saves costs in many areas:

  • Save Shipping costs due to smaller package size
  • Reduce back fill material
  • Save storage costs due to reduced number of case sizes required
  • Save of labour costs labour due to automation.

To read more details on the Vario 558 Volume reducing case closer click here.

Opitz installs Case Erector at Internet Business fulfillment Centre

Opitz has installed another Case erector at a Fulfilment centre in the midlands. This is the second case erecting machine to be installed at this customers site. The fulfilment centre is for internet orders that are picked direct to the end customer.

Opitz has installed another Case erector at a Fulfillment centre in the midlands. This is the second case erecting machine to be installed at this customers site. The fulfilment centre is for internet orders that are picked direct to the end customer.

Wide Format Range

The GO 795 is set up to run 13 formats from small cases 350 250 mm footprint up to large 800 mm long cases. The GO 795 case erector can be changed over in minutes.

Case Erector
Case Erector

Options for Bigger Cases

The GO795 can be customised to make larger boxes, for example for flat furniture packs. The GO 795 is also available with two magazine allowing the operator to set up the machine with a second format and produce two cases at the same time.

Raupack takes on Agency for the Experts in Serialisation, Hicof

The new Amacoder Track and Trace Tamper evident labeller marries serialisation project hardware and software. The result is a turnkey solution that is compact on the ground in the packaging line but whose reach extends to cover all aspects of data integration to Serialisation Authorities, Partners and beyond.

Turnkey Hardware and Software Serialisation solution for Contract Manufacturers in the Pharmaceutical Industry

Hicof are experts in Serialisation. Their new Amacoder Track and Trace Tamper evident labeller marries serialisation project hardware and software. The result is a turnkey solution that is compact on the ground in the packaging line but whose reach extends to cover all aspects of data integration to Serialisation Authorities, Partners and beyond.

The Hardware: Amacoder Track and Trace Machines

Amacoder serialisation track and trace tamper evident labeller availbale in UK and Ireland from Raupack
Amacoder serialisation track and trace tamper evident labeller

The compact Amacoder machine is only 1 metre long fitting into nearly every production line. At the infeed a pusher pushes oncoming carton into the machines main transport. Cartons are transported back to back without any space between cartons. This shortens the machine considerably. An inkjet printer prints all serial data onto the carton.  A label applicator  applies the Tamper labels. A Hicof camera system verifies the Print. Changeover is fast and simple, carried out in less than 10 minutes, formats are saved on the machines recipe system and guides are quickly adjusted.

The Software: Amacena – GxP Compliant Cloud based Serialisation Data Integration

Level 1 to 3 data integration are included in the machine purchase as standard. These process line control, serial numbers in the machine, rejects, batch records and sampling as well as communication with the Marketing Authorisation Holder (MAH) through private data hubs.  Level 4s serial number generation and communication with authorities (e.g. EMA, FDA) are available as options.

Serialisation machinery and software schematic
Serialisation machinery and software schematic

Swiss Quality, Delivered Fast and Competitively Priced

Hicof is based in Switzerland and have over 18 years of experience in serialisation. They offer both hardware and software support. The Amacoder machine is available on a fast delivery. A turnkey machine and date integration package is extremely competitively priced. As a result the overall investment to meet regulatory compliance is low both in terms of time and money.  To complement the Amacoder Track and Trace labeller they also offer the Amajoiner semi-automatic case labeller for serialisation and aggregation designed for contract manufacturers and small batches. Hicof also offer serialisation software only solutions.

AMAJOINER serialisation case labeller
AMAJOINER serialisation case labeller

Monoblock Liquid Filling Machine for Deodorant and Perfumes

Rudolf Deckert Ships Monoblock Liquid Filling and Closing Machine to manufacture perfumes and Deodorants

The FVR Monoblock liquid filling machine combines filling, screwing, capping and weighing into one machine capable of 100 containers per minute. The modular monoblock design packs these features into around 8m of length.

The customer, a cosmetics manufacturer with a focus on natural products, already had Deckert machines of previous generations to the FVR Monoblock liquid filling machine. Unlike its predecessors, the FVR combined multiple closing stations, check weighers and filling pumps into a single modular machine. This reduced the space and change parts required.

Cosmetics Monoblock Liquid Filling Machine FVR
Cosmetics Liquid Filling Closing Machine FVR

Designed to meet the customers specific requirements the machine was built with capping stations to handle roll on deodorants, over-caps as well as pump spray heads with dip tubes. Many products that run on the machine require a combination of closures to be applied on the machine, e.g roll on balls as well as screw caps or lotion spray closures as well as over-caps.

Filling at 100 per minute with in Place Cleaning and Sterilisation

Eight filling nozzles follow the bottles as they index through the machine. Cleaning and sterilisation can happen in place (CIP, SIP). Fill volumes are controlled from the HMI and can be saved in the recipe. The pumps draw the liquid from IBC containers located behind the machine. Changeover of the liquid is simple: choose the recipe from the menu and bring the right liquid to the machine. The machine will do the rest.

Filling Machine nozzles following bottles through machine on linear servo drive
Filling Machine nozzles following bottles through machine on linear servo drive

Quality Assured – Weighing and Closing

Mounted under the rake of the machine, before and after the filling station, are load cells that measure gross and tare weights for every fill on the machine. This 100% control is saved to the machines batch records and can be downloaded for quality control purposes.

The final screwing station is fitted with servo drives which accurately control the final application torque of the screw closure. Like the weight results, these values are stored and can be downloaded.

Cap presence and placement is monitored as well as bottle presence before filling.

Screwing of over-caps for roll on deodorant bottles
Screwing of over-caps for roll on deodorant bottles

Monoblock liquid filling machine makes Changeovers fast and repeatable

The use of pucks on the monoblock liquid filling machine and the FVRs automatic height adjustment makes changeover of containers simple: the pucks must be exchanged and the containers switched. Selecting the correct recipe from the HMI will cause all stations to adjust to the new container height.

Precise palcement of spray pumps with dip tubes
Precise placement of spray pumps with dip tubes
FVR-Capping-machine-overcap-placement
Overcap placement for perfume bottles

Tailored to the customers Demands

Deckert are known for their willingness to tailor there machines to their customers specific requirements. In this case, the machine needed to fill from 40 ml to 200 ml at 100 bottles per minute. The viscosity of the liquid varies from pefume to lotions (i.e water to cream). The customer specified the pump manufacturer.  The closures also vary widely ranging from deo balls to spray pumps with dip tubes and over-caps.

Placement of roll on deodorant closures
Placement of roll on deodorant closures

It is important to the customer that the hoppers for closures are accessible from the operator side. The bunkers are located on the operator side and elevators transfer the closures to the bowls that are located on the back side of the machine.

The FVR  is part of Rudolf Deckerts range of modular, monoblock filling machines for tablets, powers and liquids. Hallmarks of the AVR Capping machine series of machines are:

  • Compact Footprint
  • Fast and repeatable changeovers
  • Minimal change parts
  • Servo controlled cam movements for filling and closing that can be edited from the HMI and saved in the recipe.
  • High level monitoring and reporting.

 

Volume reducing case sealer wins Innovation prize

Raupack has recently taken on the Agency for Opitz Maschinentechnik who in 2016 won an innovation award for their Volume Reducing Case Sealer, the Vario 558. This volume reducing case sealing machine will close cases of differing footprint and heights on the fly.

Raupack has recently taken on the Agency for Opitz Maschinentechnik who in 2016 won an innovation award for their Volume Reducing Case Sealer, the Vario 558.

The growth of internet orders has seen a growth in the dispatch of packages of unpredictable dimensions making flexibility the new manta. The resulting required flexibility has often meant that automation is cost prohibitive. This is because automatic case sealers need to be able to handle packages of different footprints and heights. Further, for dispatch operations to minimise costs dead space inside the box needs to be eliminated so that costly backfill products are no longer needed and shipping costs are reduced. The environmental and financial benefits of these material reductions are self-evident. The Opitz volume reducing box sealer provides is a machine that pays: both to the customer and the environment.

The Vario 588 meets the challenges set by Logistic and dispatch operations for both flexibility and presentation:

Flexible Case Sealing – One size fits all!

One size fits all now applies to the Vario 588. This volume reducing case sealing machine will close cases of differing footprint and height on the fly. This makes it ideal for dispatch operations where the case sizes are constantly varying.

The vario 558 volume reducing case closer is used in industries from Electronic components to Clothing
The vario 558 volume reducing case closer is used in industries from Electronic components to Clothing

Good looking packages

The Vario 588 Case sealer automatically measures the height of the contents of the case and cuts the box down to just above the level of the contents. The taping mechanism moves locate the tape line over the flap edge. The result is a case that looks professional. The ability to cut down the case height allows the dispatch operation to reduce the number of case sizes that need to be stocked.

Good Looking Cases. The taper moves to cover the flap edge
Good Looking Cases. The taper moves to cover the flap edge

Self-adhesive or Gummed Tape

Opitz has a history in gummed tape application. A gummed tape bonds natively to the cases fibres and forms a seal suitable for air freight. The finish is attractive, can be printed and recycled. The Vario 588 volume reducing box closing machine can be supplied with either Gummed tape or self-adhesive tape.

Flexibility is part of Opitz Maschinentechnik’s DNA.  Their machine range can be adapted to suit the size of the box as required. Other products from Opitz include the GO 795 family of case erectors. These can be fitted with multiple magazines to allow different size cases to be erected on the fly making them the natural partner of the Vario 588 box volume reducer.

Raupack to supply Aranow stick pack and sachet machines

Whether you are in the Pharmaceutical, Diagnostics, Chemicals, Food, Beverage, Dairy or Cosmetics industry, Aranow provide a range of stickpack machines to pack both wet and dry products. These range from low scale development units with maximum 4 lanes up to high speed lines with 24 lanes.

We are delighted to announce that RAUPACK is expanding their range of packaging machinery by becoming agents of world-leading stick pack and sachet machinery manufacturer Aranow Packaging Machinery. Aranow are already represented by more than 80 agents worldwide and we look forward to introducing their machines in the UK and Ireland.

Whether you are in the Pharmaceutical, Diagnostics, Chemicals, Food, Beverage, Dairy or Cosmetics industry, Aranow provide a range of stickpack machines to pack both wet and dry products. These range from low scale development units with maximum 4 lanes up to high speed lines with 24 lanes.

The Aranow stick pack and sachet machines sit comfortably in Raupack’s machine range where quality, changeover and flexibility are central.  The flexibility and modular design of the stick pack machines allow us to handle and fill powders, liquids and tablets with various filling technologies on the same machine. Changeover between auger, volumetric system, piston pump, flowmeter or counter is extremely fast.

The key advantages of our stick pack machines and sachet machines are their reliability and repeatability thanks to their servo-driven systems: Both the filling and heating elements can be individually controlled from the HMI. High production performance (OEE>95%) and cost effectiveness (up to 40% of film savings) are also amongst the main benefits of this machinery range. Quick and easy cleaning and tool-less changeover are possible due to the easily adjustable and removable moving parts.

We can tailor our machines for any special requirements you may have, such as nitrogen flushing, special design finish for the product or if you require multiple filling systems on the same machine frame. We can also combine the stick pack machines or sachet machines with secondary packaging or end-of-line equipment such as baggers, flow-wrappers, cartoners and case packers which are all in our machinery portfolio.

Please visit our website or get in touch for more details and we will be happy to help you with your project.

Automatic Broken Tablet Rejection on Tablet and Capsule Counting Machines

At Interpack 2017 Cremer and Deckert both showcased Cremer counters with camera inspection systems and automatic reject of individual capsules. Camera detection of broken, rogue or discoloured tablet or capsules is nothing new, however previously reject took place either manually or a container was rejected. To ensure the rejected tablet or capsule was rejected often more than 1 container was rejected. The new automatic broken tablet rejection systems presented at Interpack involved pneumatic suction systems that automatically removed the defective tablets or capsules from the infeed tracks. This new approach maximises yield while minimising downtime.

At Interpack 2017 Cremer and Deckert both showcased Cremer counters with camera inspection systems and automatic reject of individual capsules. Camera detection of broken, rogue or discoloured tablet or capsules is nothing new, however previously reject took place either manually or a container was rejected. To ensure the rejected tablet or capsule was rejected often more than 1 container was rejected. The new automatic broken tablet rejection systems presented at Interpack involved pneumatic suction systems that automatically removed the defective tablets or capsules from the infeed tracks. This new approach maximises yield while minimising downtime.

https://www.youtube.com/watch?v=Vd1q1avwkoQ?rel=0

Automatic Tablet Reject on Standalone Counter

On a standalone counter like the CFS 622 shown above once a defect is identified, a pneumatic arm moves across the 36 channels to remove the detective tablet or capsule. After this the machine restarts without having to reject a container.

Automatic Tablet Reject on Cremer Counter Integrated into Deckert TVM Monoblock counter

On the TVM a single CF622 module with 6 channels counts the tablets into bottles. Here the reject mechanism consists of 6 pneumatically actuated reject arms, one for each channel. The arm moves quickly to remove the broken or otherwise rejected tablet.

Monoblock Rotary Filling Capping on which Automatic broken tablet rejection can be fitted 
Monoblock Rotary Filling Capping on which Automatic broken tablet rejection can be fitted

Reject Criteria for Automatic Broken Tablet Rejection

The automatic tablet reject system can reject for the following causes.

  • Broken pieces by pixel count
  • Broken pieces by length or width
  • Colour defects
  • Spots
  • Rogue tablets
  • Open capsules

The camera looks from above and is restricted to what it can see above. In order to improve the camera’s viewing angle and narrow tolerances, flat camera plates can be fitted to the Cremer. These improve the aspect ratio visible to the camera. These flat plates optimise the contrast to the tablet as seen below.

Flat Camera Plates on Cremer Tablet Counter
Flat Camera Plates on Cremer Tablet Counter

Deckert Delivers Compact Tablet Counter with Glove Ports

Rudolf Deckert has just delivered their popular TVM mono-block tablet counting line fitted with Glove Ports. The customers cancer drug is both dusty and toxic to the operator. Therefore the Tablet Counter and all sorting bowls were covered with polycarbonate hoods. Inside the machine guarding extraction caused an under pressure minimising the escape of toxic dust. Any operator interventions could take place through the glove ports. A rapid transfer port (RTP) was fitted to the tablet infeed to allow containing product loading

Rudolf Deckert has just delivered their popular TVM mono-block tablet counting line fitted with Glove Ports.

TVM Tablet counter with glove ports

The customers cancer drug is both dusty and toxic to the operator. Therefore the Tablet Counter and all sorting bowls were covered with polycarbonate hoods. Inside the machine guarding extraction caused an under pressure minimising the escape of toxic dust. Any operator interventions could take place through the glove ports. A rapid transfer port (RTP) was fitted to the tablet infeed to allow containing product loading.

The TVM tablet counter had most of the functions that this series of machines are known for: Air Cleaning with deionised Air, Counting, Broken Tablet inspection, Capping, Induction Sealing and Re-torqueing. A sensor verified the presence of aluminium in the foil.

As a special feature vinyl sponges or oxygen scavengers in barrel form can be inserted after gross weighing. The sorting device, feeding track and transfer station can be purged with nitrogen gas to extend scavengers duration time inside the machine.

The Cremer counter has 6 vibratory feeding lanes controlled by 2 servo drives. The increased movement control that the servo drive offers has allowed us to achieve in 6 lanes what had required 12 lanes on standard vibratory tracks. The servo drives can be fine tuned for each product and those settings saved in the recipe. The tablet counter is also fitted with automatic feeding plate removal. At the touch of a button the vibratory plates lift to allow the operator to easily remove the product contact parts for cleaning. The vibratory plates are either V shaped or dedicated format specific flat plates. Aspirated hoppers under the feeding plates keep dust away from the feeding tracks.

A camera system looks for broken pieces or miscoloured tablets.

Faster Changeover – Choosing the Right Recipe

Our tablet counting lines share one important characteristic: The recipe controls nearly everything. Timings on cap application, vibration settings of the tablet feeding tracks as well as the measuring window of integrated weigh cells are all stored in the recipe. The fact that most drives are servo drives allows for more control of critical machine functions form the PLC. Unlike pneumatic and mechanical CAM based technologies many settings can be adjusted and saved into the HMI. It is not necessary to adjust cogs and regulators underneath the machine table between format changeovers. This means that changeover is faster and more consistent. The TVM  mono-block counting line has the advantage that a single star-wheel presides over all operations. This means that changeover parts and therefore changeover time are greatly reduced. The TVM can also be fitted with a integrated labeller and with weigh cells under the star-wheel.

The video below shows the TVM with Air Rinse, Integrated Gros-Tare weigh, Cap, Re-torque and label application – all in a small foot-print.

Read more about this machine on our webpage: http://www.raupack.co.uk/machinery/monoblock-capsule-and-tablet-counter.aspx

 

Barry M satisfied with vertical cartoning machine

One of the leading brands in the cosmetics industry, Barry M have recently purchased a fully automatic vertical cartoning machine to pack nail varnish bottles into cartons. The machine was delivered to their main manufacturing site in London and they couldn’t be more satisfied with the system since.

One of the leading brands in the cosmetics industry, Barry M have recently purchased a fully automatic vertical cartoning machine to pack nail varnish bottles into cartons. The machine was delivered to their main manufacturing site in London and they couldn’t be more satisfied with the system since.

The initial discussions started by identifying the challenges Barry M faced with their production and the opportunities to improve their operation. The main objective was to come up with cost effective solutions that had the best return on investment.

The outcome was to use a fully automatic cartoning system which included bottle orientation before pick and place loading into cartons vertically [picture below] and the use of a print system to print barcodes.

Vertical cartoning machine with automatic product insertionOne of the problems Barry M faced was the lack of speed of the manual packing operation. On occasion the manual operation damaged the separators in the carton during packing. These issues were solved on the machine by using mouthpieces to guide 3 bottles into the carton at the same time, significantly increasing output. The project also delivered a mechanical verification station to confirm that all the bottles were fully loaded into the cartons. This ensured there was no potential damage to the carton during closing.

After the vertical cartoning machine was delivered the customer added a turntable to the line to eliminate the manual labour that was required to load the bottles. The turntable feeds a conveyor belt with side-belts which singulates and aligns the bottles ready for loading into the carton.

Vertical cartoning machine for nail varnishes

Space saving design

The biggest challenge Barry M faced was the available space they had for a potential equipment. They required a vertical cartoning machine with a footprint of less than 4m2. The room also contained concrete columns which had to be taken into consideration. The compact machine and clever design made it possible to install a machine that met all of the customer’s requirements.

The speed of the machine was sold to pack at least 30 cartons per minute packing 90 nail varnish bottles in threes every minute. However, the machine can run comfortably at more than 35 cartons per minute speed exceeding the customers 100 bottle per minute milestone.

OCS Checkweigher with Reject available for immediate delivery

Raupack has an OCS EC-E checkweigher available for immediate delivery.

The checkweigher, available for immediate dispatch, consists of a weigh cell, an infeed and outfeed conveyor as well as an integrated reject with lockable container. A touch screen and electrical cabinet control the unit.

The OCS EC-E checkweigher has a weighing range of up to 1500g, display value of >=0.2g and a maximum dead load of 8.5kg. The checkweigher is supplied with installed batch recording software. The batch records allow identification and storage of up to 50 different products in the recipe system. New products can be entered on the touch screen. Different operator permission levels can be set. It is possible to export the results to a USB stick. The software can optionally be connected to a network by comscale.

The reject uses an air knife to blow the product into an integrated bin.  As well as weighing the product, a sensor checks the length of the products. If the products are too close together, or if a long rogue product passes the weigh cell, it will be rejected.

For Sale or Rent CCM-MV Hand Load Vertical Cartoner Exhibited with Checkweigher

The OCS Checkweigher was exhibited at the PPMA show with the popular CCM-MV semi-automatic cartoner. The CCM-AV cartoner is available for rent or purchase. The operator loads the products into the carton manually. All other cartoning functions are automatic. It has the capability to produce both tuck and glue cartons. Changeover is fast taking approx. 10-15 minutes. The operator controls the pace of the cartoner, waiting for the light barrier at the loading position to become free before indexing. A printer prints batch information on the cartons underside. A capacitive sensor verifies that the product is in the box. If the product is not present then the machine displays a message and waits for the operator to try and load the product again.