Professional Documents
Culture Documents
Packaging Equipment
Many types of equipment have been used and are being used for packag-
ing snacks, but the generally fragile and bulky nature ofthe products and
the advantage of being able to apply inexpensive packaging materials
have led to the predominance of pouch-forming equipment in this indus-
try. The measuring process is an essential part of the packaging system,
and from hand-filling with volumetrie scoops it has advanced through an
evolutionary series of changes to automatie weighing and filling on very
sophisticated high-speed pouch formers.
Although equipment designed for packaging other products such as can-
dy, cookies, granular materials, etc., has been adapted for snacks and is
still utilized quite successfully for certain of these items, the extremely
variable shapes and densities of snacks such as potato chips and popcorn
has necessitated the development of specialized equipment. Within the
space limitations of the chapter, only a few of the most important alter-
natives can be discussed. For more extensive treatments of general types
of packaging equipment, the reader should consult Principles of Food
Packaging, Second Edition (Sacharow and Griffin 1980), Principles of
Package Deuelopment (Griffin and Sacharow 1972), and Package Produc-
tion Management, Second Edition (Raphael and Olsson 1976).
FOLDING CARTONS
Folding cartons made of paperboard are used for many baked snacks,
although they do not offer sufficient protection against moisture vapor
protection to be satisfactory for the more hygroscopic products. For the
latter items, cartons can be used to enclose hermetically sealed pouches of
moisture-resistant films, giving an improved appearance and considerable
protection against crushing.
Folding cartons can be classified as either tray style or tube style. The
tray-style cartons are formed from paperboard with the sides folded at
right angles and locked, glued, or stitched together at the corners. Com-
bination top and bottom units can be formed from two trays, or one panel
can be extended and folded to form a cover.
The tube-style cartons are made from a sheet of paperboard which is
folded over and then glued to form a rectangular sleeve. The panels that
293
FIG. 22.1. Equipment for setting up preformed boxes and filling them with a
weighed amount of product.
Courtesy of Wright Machinery Division, Rexham Machinery Group.
form the ends may be fixed in plaee by applying adhesive, tucking exten-
sions into folds, or interloeking sIit tabs.
It is generally recognized that the tray style offers greater strength than
the tube version. It can also be loaded from the top, which is often more
eonvenient than the end loading of the tube style. Many variations of
design are possible.
In almost every ease, the cartons are delivered to the user in knoeked
down form . Setting up, filling, and sealing ean be done manually or with
automatie equipment in any desired combination offunctions (Fig. 22.1).
Aceording to Knapp (1983), eartoning maehines ean be eategorized ae-
eording to (1) mode of operation (semi- or fully automatie), (2) loading
direction (vertieal or horizontal), and (3) type of motion (eontinuous or
intermittent). A semi-automatic eartoning maehine requires the operators
to pI ace the product in the earton manually. In the fully automatie mode,
the produet is automatieally loaded into the earton. Semi-automatie ear-
toners are more appropriate where many different sizes and frequent
ehangeovers will be required on a given paekaging line. They normally
eomplete 30-150 cartons/min. Fully automatie eartoners usually have
high-speed eapability but less size range than the semi-automatie ma-
ehines.
PREFORMED POUCHES
FIG. 22.2. Model 51-CK packaging system forms a bottom-gusseted bag from
roll-stock film, fills the bag with a snack product, closes the bag with a twist tie, and
discharges the completed bag into a registered moving line of Sealright Chipkan
paperboard canisters.
Courtesy of Bodolay Packaging Machinery. Inc.
296 SNACK FOOD TECHNOLOGY
FORM-FILL-SEAL EQUIPMENT
Most of these machines fall into two categories: the vertical type, which
generally forms a tube by making a continuous seal down the middle ofthe
back side of the moving film, and the horizontal, which usually forms a
trough or U-shaped cavity of film that is then separated into compart-
ments by vertical heat seals before it is filled. The former is much more
common in the snack industry, although horizontal equipment is used for
nuts and similar dense products. Other types of pouch formers are also
used occasionally for snacks.
In vertical form-fill-seal equipment, the film is drawn from a roll under
tension and carried over a "collar" ofunique geometry which shapes it into
a cylinder. The film-at this point still open at the edges-travels down
and around a metal tube through which the product will be dropped. The
back seal can be made by pressing a hot sealing iron, often bar-shaped,
against the apposed edges ofthe film, using the tube as a back-up surface.
This gives an overlap seal. Alternate arrangements can give a face-to-face
22 PACKAGING EQUIPMENT 297
PROOUCT PROOUCT
or fin seal. Two webs can be used, in which case heat seals are made on
four sides (see Fig. 22.3).
The motive power for the web movement is provided by horizontal seal-
ing jaws that pull the film downward the length of one pouch in each
sequence. These jaws simultaneously form two end seals (top seal of the
bottom pouch, bottom seal of the top pouch of the set). The film may be
severed by the action of a knife in the heat-seal bars, or the cutoff may be
made by aseparate device.
After these steps are completed, the draw bar opens and is returned to
the top of the next pouch. During this return movement, the product is
dropped through the metal tube into the open mouth of the half-formed
pouch (Muskat 1983; Anon. 1982).
The hot-tack seal at the bottom of the tube must form very rapidly and
be strong enough to resist the weight of the product attempting to force it
open. Many packaging materials, such as glassine and uncoated cel-
lophane, will not form such a seal. and coatings of nitrocellulose, rubber
polymers, PVDC, etc., must be applied to give the necessary properties.
Under certain conditions seals can be made to polyolefins and some other
films.
The he at-seal material may be applied as an overall coating or layer or
as a thermal stripe limited to the area in which the seal is to be formed.
Methods of sealing, and the related equipment, have been listed by
Young (1983) as:
Bar Friction Solvent
Band Hot gas Electronic
Impulse Contact Magnetic
Hot wire Hot melt Induction
Ultrasonic Pneumatic Radiant
298 SNACK FOOD TECHNOLOGY
In actuality, only bar sealers and impulse sealers are used to any signifi-
cant extent in the pouch packaging of snack foods. The transverse seals
are applied to the pouch either by the heated bar method, where two
heated metal jaws (either smooth or serrated) push the two sealable sur-
faces together, or by a combination of one heatedjaw and an unheatedjaw
covered with a flexible insulating pad. Heat is supplied to the jaws contin-
uously by cartridges containing resistance elements that are fitted into
the jaws. Normally, a relatively constant temperature is maintained by
controlling the current flowing to the cartridge. These systems work satis-
factorily with laminates based on cellophane, polyethylene-coated paper,
and foil-Iaminates, as well as some other substrates. When plastic films
such as LDPE are to be sealed together, a thermal impulse system may be
needed. These devices supply a sudden large surge of heat by applying
variable voltage across a nichrome ribbon. Impulse sealers are constructed
very much like bar sealers, except that both ofthe sealing jaws are covered
with resilient silicone rubber. A nichrome ribbon is held in a stretched
condition over one or both ofthese surfaces, and the ribbon itselfis covered
with Teflon®-impregnated fiberglass or Kapton.
The back seal or longitudinal seal that converts the strip of film into a
tube is usually formed by a heated bar that presses the two layers against
the filling tube. A minority of equipment is being sold with more elaborate
types of vertical sealing units.
Conformations of the sealing jaws, temperatures, dweIl times, and some
other factors will be different for each different sealant combination.
The tube and former assemblies must be changed when bag width is
altered. Sometimes a change in the film composition will also necessitate
use of a different assembly. Dimensions, shape, materials of construction,
surface finish, and other characteristics of the forming head have marked
effects on the efficiency of pouch forming and on the damage done to the
film. Some heads that give excellent results with cellophane will not func-
tion properly with polypropylene or paper, etc. The factors governing the
film and former interaction seem to be rather inadequately understood,
even by the engineers of the packaging machine companies.
Many of the available machines have unique design features intended
to give superior performance, at least for certain li mi ted applications.
Examples are:
1. Hayssen equipment can use powered rollers to exert additional force
in pulling film from the roll.
2. The Rovema filler distributed by Pneumatic Scale Corp. uses rubber
wheels to push the pouch material down the tube and past fixed
sealing and cutoff jaws. Gusseted pouches can be made on the
Rovema.
3. Mira-Pak equipment eases the fall of product by carrying it down to
the pouch in a moving cup. Breakdown of fragile materials such as
potato chips is minimized.
4. In Woodman equipment, the tube is slanted so as to reduce product
momentum when it falls into the pouch.
22 PACKAGING EQUIPMENT 299
FIN SEALON
FIG. 22.5. Sealing method PACKAGE BonOM
used on horizontal wrapping
equipment.
COUltesy of Doboy Packaging Ma-
chinery Div.
PRECISION
CUTOFF KNIFE
REQUIRES ABSOLUTE
MINIMUM MAINTENANCE
tal wrappers are examples of this type of equipment. They can pack up to
400 units/min and accommodate a wide range of container sizes and con-
figurations; they are recommended for use with soft cakes, sweet goods,
cookies, crackers, baked health food products, and candy bars. Some of the
features claimed for these machines include solid state proportioning heat
controls, a control panel that swivels 270 to provide easy viewing for
0
operating and servicing, crimping head with infinite adjustment for vari-
ous cutoff lengths, three sets of fin wheels for positive web control, and
sanitary cantilevered construction. Automatie feeding systems are avail-
able for most wrapping operations.
Figure 22.5 diagrammatically indicates the package sealing system
used on Doboy H-series horizontal wrappers.
Product-measuring Devices
The equipment for measuring the amount of product to be deposited in
each bag is generally separate from the form-fill-seal machine, although
manufacturers of the latter devices will usually supply integrated sys-
tems. Auger, bucket, volumetrie, and net weighers as weIl as counting
devices can be used to measure out the portions.
The Wright Model AC is an advanced type of counter with seven heads
(Fig. 22.6). The electronic counting system consists of a receiving hopper
serving a multiple-head counter of modular design with individual
vibrator feeds for each counting head, and a remote control station. Prod-
FIG.22.6. Model AC Counting Filler with seven heads.
Courtesy of Wright Machinery Division, Rexham Machinery Group.
FIG. 22.7. An in-line system for weighing and filling free-flowing products into
rigid containers such as composite cans.
Courtesy of Wright Machinery Division, Rexham Machinery Group.
302 SNACK FOOD TECHNOLOGY
uct is supplied into a channelized hopper, from each channel ofwhich the
individual pieces are fed through aseries of vibratory feeders where the
flow is automatically modulated and the pie ces are oriented into single
file. At this point, there is a very narrow section designed to spill off any
pieces that may be going through side by side or piggyback. The pieces to
be counted, now flowing in single file at elose intervals, ride over a rotat-
ing wheel, which accelerates them, putting enough space between them to
allow them to be counted with a light beam and a photoelectric cello The
counted pieces drop directly into the lower compartment of a batch ac-
cumulator or bucket. When the desired count is reached, an angular but-
terfly gate shifts to create a temporary upper compartment in the bucket,
and the counter resets to zero and begins counting and accumulating a
succeeding batch into the upper compartment. A trap door opens in the
bottom of the bucket, dropping the counted batch into a carton or other
container. As the trap door eloses, the butterfly gate shifts back to its
original position, allowing the accumulated pieces to drop into the lower
compartment. To synchronize the dumping of the precounted batches into
containers being supplied at a uniform rate, the dumping of each batch is
delayed slightly when necessary to allow the container to move into the
proper position, and the feeding of pieces to the counter is interrupted for
the same amount oftime. The solid state counter can be set for loads ofup
to 99 pieces, and counting rates up to 300 pieces/min/counting head are
possible. Equipment ofthis type is suitable for counting relatively uniform
pieces of intermediate size.
The Wright Model FA in-line modular weigher system (Fig. 22.7) can be
used for weighing and filling free-flowing products into rigid containers.
The system consists of 2-6 Electroflex scales and a package indexing
conveyor for handling cartons, jars, and cans. The product is received from
a continuous processing conveyor or low-Ievel feeder into a specially de-
signed, balanced, channelized surge hopper. Aseparate product flow con-
trol system at each transfer point provides a smooth and continuous flow
to each weigh bucket. The bulk product feed system is equipped with
vibrators to separately control bulk- and finish-fill feeders. The finish-fill
fee der is V-shaped to single file products for the final weight.
The electroflex scales are said to have such features as cross flexure
pivots, zero pendularity, zero stress in beam at the point ofmeasurement,
and balanced beam with mechanical application. Detection is achieved by
contact points on alever, which activate asolid state relay. Wright elaims
that the solid state correct weight detector allows instantaneous finish-fill
control that remains stable throughout a wide temperature range. during
li ne voltage changes, and under adverse environmental conditions.
The weighed product enters individual product chutes that are mechan-
ically lowered into the package, eliminating spilling and allowing the
product to settle prior to discharge. The package-indexing conveyor is
equipped with a product-settling device, package flow controls, and dual
indexing mechanism.
Rotary net weighers provide relatively high rates ofmeasuring product.
The Wright Rotary Net Weighers (Rexharn Machinery Group) can be
22 PACKAGING EQUIPMENT 303
FIG. 22.8. A vertical form-fill-seal machine with auger feed for powdered
materials.
Courtesy of Wright Machinery Division, Rexham Machinery Group.
304 SNACK FOOD TECHNOLOGY
FIG. 22.9. A tumble filler for placing irregularly shaped pieces into rigid con-
tainers.
Courtesy of Solbern Corp.
22 PACKAGING EQUIPMENT 305
These packages and the equipment for filling and sealing them are
distributed by the Interstate Folding Box Co. ofMiddletown, OH. Prelined
bag-in-box containers are delivered flat; they are then erected, the bag is
heat sealed, and the box is closed on Rotoseal equipment. Weighing and
dumping are done on separate equipment not sold by this firm. As deliv-
ered by the supplier, the bag material is sealed at the side and open at the
top and bottom. It is also glued to the inside of the box so that the bag
opens as the box is squared up. All seals are fin or face-to-face seals, and
the liners are made of laminates of films and foils. Capacities are from 15
to 420 in. 3 .
The basic Rotoseal equipment produces up to 30 finished packages/min,
and this can be doubled by adding an automatic infeed-transfer unit. A
second Rotoseal and auxiliary equipment can be used to increase the line
speed to 120 units/min. One or two operators are said to be required.
Height changes within a certain range can be made by simple adjustment
of the machinery, but alterations in other dimensions require change
parts.
Package design options offered by the Interstate Folding Box Co. in-
clude boxes with handles on a gable top, push-pull pour spouts, two sec-
tioned inner bags and dispenser packs.
306 SNACK FOOD TECHNOLOGY
From one dozen to 100 pouches, depending on size and retailer require-
ments, are ordinarily packed in corrugated shippers before they enter the
distribution system. An extra labor charge is involved which manufactur-
ers would like to minimize. Neodyne Industries, Inc., has developed equip-
ment for the automatic performance of this operation.
Neodyne's equipment check weighs each pouch, assembles a set of
pouches in the configuration needed for one layer, then picks up the layer
with vacuum cups and deposits it in a shipping case. Adjustments can be
made for size ofpouch, number ofpouches in a layer, number oflayers in a
case, and speed of delivery.
Neodyne claims its equipment can permit about 10% more output from a
form-fill-seal machine by eliminating the human constraints on case
packing.
The Standard-Knapp Flexible Bag Packer performs a similar function,
although design features are different. Bags are taken directly from the
form-fill-seal machine and each bag is checked individually for weight.
The seal on each bag can also be checked, if desired, and any package that
fails the weight or seal check is automatically rejected. The accepted bags
are accumulated and then placed into an empty corrugated case that has
been automatically set up and moved into loading position. Speed varies in
the range of 25-110 bags/min, depending on the model.
REFERENCES
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New Richmond, WI.
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BALL, C.O. 1963. Flexible packaging in food processing. In Food Processing Opera-
tions, Vol. 2. J.L. Heid and M.A. Joslyn (Editors). AVI Publishing Co., Westport,
CT.
BRICKMAN, C.L. 1957. Evaluating the packaging requirements of a product. Pack-
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GRIFFIN, RC., JR and SACHAROW, S. 1972. Principles of Package Development.
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HUGHES, W.P. 1982. A procedure for purchasing and installing a packaging ma-
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the new. Package Dev. 1974 (Jan./Feb.l 23-30.
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MEMBRINO, J.N. 1974. Do you know the impacts temperature and humidity
changes make on polyethylene films? Package Eng. 19 (12) 52-55.
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Edition. AVI Publishing Co., Westport, CT.
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