Your individual product - our individual solutions

For the production of filled potato products with different shapes, our customer was looking for a solution that would ensure three things:

• Weight-accurate portioning
• Centered placement of the filling
• Secure closure of the product casing

In the downstream processing stage, the potato products are transferred to a deep fryer.

A four-lane servo crimper was chosen due to its outstanding precision and high process reliability. The solution reliably meets all requirements and creates the basis for an efficiently scalable, industrial production volume.

The focus of this project was maximum flexibility - both in terms of portion sizes and the products to be processed. Various pet food products were filled in a 3.2 and a 6.8 thermoformed pack with a wide weight range from 50 g to 500 g.

A key requirement is that a combination pack can contain two different products. The solution must therefore be able to be operated reliably with both a single and two vacuum filling machines.

At the same time, a clean filling pattern without product residue in the sealing area and high weight accuracy are crucial for the overall process.

The solution is implemented using two filling flow dividers with six or twelve chambers in combination with two filling stations, each with six lowerable filling heads - for precise, flexible and stable production processes.

In this project, different types of cheese were processed into variable product shapes - from square and round slices to star-shaped pucks. The decisive factors were precise shaping, a clean cut and maximum weight accuracy.

A 10-lane flow divider (flexibly convertible to 5-lane) with an electronically driven cutting unit (wire cutter) is used, which achieves outputs of up to 200 cuts per minute. The angle of the cutting unit can be flexibly adjusted from 0 to 60 degrees.

An integrated water spray system and heatable outlets ensure reliable processing of the different types of cheese. The products are deposited on a 600 mm wide depositing belt - stable and reliable.

The aim of this project was the precise filling of a medium-viscosity fish mass into cans with a high degree of flexibility in terms of container sizes and formats.

Clean, drip-free filling behavior and high weight accuracy were particularly important to the customer. The focus was on a uniform filling pattern and the avoidance of product residues in order to ensure reliable further processing and minimal give-away.

The solution combines a vacuum filling machine with a 5-lane filling head system and meets all of the customer's requirements.

For a customer with an existing thermoforming packaging machine, we developed a three-lane filling system consisting of a vacuum filling machine and filling heads, mounted on a two-axis linear system, installed in a movable stainless steel frame. With a portioning capacity of 8 cycles per minute, different portion sizes can be filled directly into the packaging machine with absolute cleanliness and accurate weight, without contaminating the sealing surface. This significantly reduces rework at the customer's premises.

Our customer's task was to form as many sticks as possible from the South American root vegetable manioc on a specified belt width of 1200 mm and portion them into a deep fryer via a conveyor belt. The sticks were to have a constant portion weight of 18 g at maximum output (144,000 sticks per hour). Our solution - a 24-lane filling flow divider with integrated cutting device - met all the requirements to the customer's complete satisfaction.

In this project, the customer wanted to find an efficient solution for denesting, filling and closing trays of different formats. Approx. 30 trays per minute were to be filled and closed with a chunky salad mixture. The customer's goal was achieved with a customized solution consisting of a filling head, rotating filling station with tray denester and sealing function. The mixture is portioned into the cups very cleanly and accurately by weight and the cups are then sealed.

The customer's requirement was to fill a prefabricated baked good with 15 g of chocolate cream. Twenty-five units of 12 buns each were to be processed per minute. With the Robot500 vacuum filling machine and a 12-lane filling flow divider with twelve adjustable injection nozzles, mounted on a pneumatically driven vertical axis and an index belt, it was possible to place the filling in the middle of the product with absolute weight accuracy.

The customer's product, meatballs, needed to be perfectly formed at maximum output and then portioned onto a frying system. It was particularly important that the meatballs retained the correct shape after the cooking process. Our solution: adapting our standard Ball Control BC236 machine to an even larger and more powerful machine - the Ball Control BC236 XL with a width of 1200 mm. Thanks to the simple exchange of the forming nozzles, other shapes can also be produced quickly and easily, offering the customer additional flexibility.

The customer's gingerbread product is produced with our customized solution, consisting of a dough portioner, 12-lane filling flow divider, cutting device and two flour dusters, at a portioning capacity of 11 kg per minute and transferred to a continuous oven. The sticky mass poses a particular challenge. To make processing easier, the conveyor belt is dusted with a layer of flour before the mass is portioned onto it. Before the continuous product strands are cut, a second duster applies flour to the mass. The product is separated cleanly and accurately by weight by a cutting device above the conveyor belt. Production is continuous and automated so that identical portion sizes can be guaranteed with the highest possible output.