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Home , Packaging machinery

PACKAGING MACHINERY is the most reliable method food containment. This is the best way to safely control and protect the food against physical, chemical, biological and environmental factors. It would be our duty as consumers to check the goods or food that we purchase in the market whether they are well packaged or sealed. FUNCTIONS OF PACKAGING: Packaging performs varied tasks such as protection of the contents in its containment from spoilage and leakage, easier transportation and storage and better communications between the manufacturer and consumer. The most important four functions of packaging include: containment, protection, convenience and communication. All these are inter-related and should be considered well before the development of any packaging. Containment: One of the most obvious functions of any packaging material is to contain its contents so that they can be easily transported and stored. It may be any pack, like a cola or a bulk cement wagon, if it does not contain the content well, the package will not be successful. Without proper containment, product loss and pollution levels would be very high. The function of containment is most important in preventing the pollution of environment. Faulty seals or under packaging often leads to leakage which might affect environment adversely. Protection: This is regarded as the primary function of packaging, i.e. to protect its contents from any external influence which maybe physical, chemical or microbiological. This protection provided by a package is an assurance for a longer of the food product. It also plays an important role in preservation process. This function protects the food from organic enzymatic reactions, like oxidative rancidity. For example, a vacuum packaged meat or meat product remains preserved only till it is not to oxygen. The packaging material acts as a barrier against spoilage causing as well as pathogenic microbes. Convenience: With the advent of modern fast world, people prefer everything convenient to handle and store. Today, manufacturers are aiming at producing foods which can be easily preheated or prepared in minimum time possible. For example, ketchups were earlier sold in which were difficult to store, but now is more commonly sold in flexible retort pouches which can be easily stored anywhere. A convenient package also improves the sales of the company as more consumers will buy it than an inconvenient one. For example, food products which cannot be consumed in one go should be packed in packs which are reseal able after use. PRODUCTION AND PACKAGING LINE REQUIREMENTS The principal factors which affect efficiency and utilization of a packaging line may be considered under three headings: 1. The suitability of the machine for the purpose 2. The output speed required 3. The likelihood and frequency of stoppages and the time taken to clear them

Some of the packaging machineries are: 1. Form, fill and seal machine 2. Cartoning system 3. Shrink and seal machine 4. Bottling system

Form, fill and seal machine These machines use a reel; of flexible material (, film or laminates of paper/film/foil) and either form it into a and then seal and fill it at regular intervals, or fold it lengthwise and seal it at right angles to the fold to form a series of pockets which are filled and closed. Form fill and seal machinery may be conveniently divided into three types: 1. Vertical machines, in which the material is formed into a circular section tu8be over a forming collar 2. Horizontal machines, in which the material is formed into a rectangular section tube through a forming , 3. forming machines, in which after filling, the remaining side is sealed to form the complete pack.

The seals in sachet are always are always made between different areas of the same face of the web, but with pouches either face to face or overlap sealing is possible on the long face seal produced in forming the tube. • Vertical form, fill and seal machine

Vertical Form, Fill and Seal (VFFS) machines are automated assembly line packaging systems used in packaging liquids and solids. Principle: VFFS machine can be intermittent or continuous motion. Intermittent motion machines operate on the principle that vertical seals are made when the film is moving and horizontal seals occur when the film stops.

Process • A roll of film is unwound and formed into a tube over a forming collar. A vertical overlap seal is applied to the tube by the vertical sealing bars. A bottom seal is created by the horizontal sealing bars in the cross jaws. • The formed pouch is then filled with correct amount of product while the film tube is being fed by the film transport belts. Often a precision scale or an auger ensures that the proper amount of product is placed in the pouch in a consistent manner. • After the correct length of film tube has been fed, a top seal of the filled pouch is created by the horizontal sealing bars, while the filled pouch is cut from the descending film tube by a knife in the cross jaws. • If the film is pre-printed, a registration sensor is added to the system to correct the film position in order to maintain the correct print position relative to the end of the pouch. The bottom seal creation of the empty pouch, top seal creation of the filled pouch and cutting of the filled pouch all occur at the same time.

Vertical form fill and seal machine can produce three styles of pack. 1. Pillow packs: these characteristically have fin or overlap seals on the base of the pack and transverse seals at either end. The most common applications are solid performed items or multipacks e.g., candy bars or chocolate enrobed biscuits and collections of smaller solid performed items. 2. Sachet packs: these have a four sided fin seal around the edge of the pack. The most common applications are [powdered and granular or similar products e.g., instant soups, instant potato, instant desserts. 3. Strip packs: This consists of two layers of material sealed together to contain the product between them in individual pockets. The most common applications are in pharmaceuticals: pills, capsules, suppositories.

Vertical form, fill and seal machinery: • The product enters the system through the forming tube. • The forming collar shapes the flat film into a round film tube. • Low friction rollers guide the film to the forming area. • Vertical sealing bars seal the edges of the film tube together. • Film transport belts pull the film through the forming area. • Cross sealing jaws create top and bottom seals in the pouches, and cut the filled pouch from the empty pouch.

. Applications: Vertical Form, Fill, and Seal (VFFS) machines are used in the consumer products industry for a wide variety of packaging applications. Various products like salt, tea, sugar, spices, snack foods, wafers, detergent and candies are placed into formed pouches and then sealed. The pouch material is flexible and typically heat-sealable plastic. Paper is also used and sealed by glue.

• Horizontal form fill and seal machine: These have much in common with their vertical counterparts. The horizontal machine combines the three separate operations of pack forming or shaping, product introduction into the pack and pack . The process also uses a reel or reels of wrapping material; the principal difference is that material is pulled from the reel into a horizontal plane where the subsequent operations take place. Process • Sequence of operations of a typical basic machine: the products are loaded into a continuously moving infeed conveyor. The type of conveyor is dependent on the product, but a chain-lug infeed is the most commonly used. • The wrapping material is formed into a tube inside a folding box. The edges of tube are fin sealed together as they pass between a pair of horizontally mounted propelling and sealing rollers. • Automatic product feeding: for pouch pack machines these may range from relatively simple units for the more common applications, to custom-designed systems to suit a particular individual requirement. • Alternative sealing systems: the type of folding box and the layout of the long seam propelling/sealing unit depend upon the packaging application and the materials used.

Advantages of FFS • made on FFS are less expensive than pre-made bags = “pay back” • Lower capital cost than fully auto machine when packing rate above 500 bags/h • Total - usually unattended, labour saving provides = “pay-back” • Consistent packing rate • Compact (especially the Vertical FFS) • Fast - increased production rate, reduced no. of shifts = “pay back” • Easy and quick to clean-out between production batches • Fewer moving parts - especially Vertical FFS • 'Online’ film provides readable bar code and product info

Disadvantages • Not economical for short production runs of one bag size - below 1000 x 25 Kg bags = 25 tons • Cannot handle paper • Cannot handle multi-ply packing materials • Not economical for packing low density, aerated powders such as wheat flour, talcum powder, skimmed and whey powder at medium speeds • Cannot remove ‘trapped air’ very quickly or easily • Shape of package made by Vertical FFS or ‘C’ type FFS not as good as valve sack • Cannot self-adjust for different widths of bag (but changing length is very easy on

Cartoning systems A Cartoning system combines a special with the machinery to erect it from a flat condition, fill it with a product, and close it. The machinery varies from simple hand-fed machines to automatic stations coupled with means for packing the directly into cases for dispatch. Main three operations are performed: 1. Forming or erecting the container: material may be fed to the carton erection point as a continuous web, as a flat carton blank, or as a folded carton flat with a manufacturer’s joint secured. 2. Loading or filling the container: in the continuous web-fed and top-loading systems, the container has only one face open at the moment of filling; with an end-loading system it is possible with certain products to load the carton and close both ends afterwards. 3. Closing or sealing.

Machinery consideration • Production rate and expected peak load • Range of pack size involved • Frequency of the change in size • Whether the existing system can accommodate changes in the pack size

Cartons for liquid products: Requirements with respect to impermeability and hygiene are particularly stringent when packing liquid food products. Sealing must be very naturally very tight, and there are problems to be solved in connection with filling and how to seal and avoid open-cut edges. • Tetra pak: The tetra-pak has principle of forming from a reel, the different stages being combined in one machine. This machine permits carton filling under fully aseptic conditions. Tetra Pak uses aseptic packaging technology. In the product and the package are sterilized separately and then combined and sealed in a sterile atmosphere, in contrast to , where product and package are first combined and then sterilized. When filled with ultra-heat treated (UHT) foodstuffs (liquids like milk and juice or processed food like vegetables and preserved fruits), the aseptic packages can be preserved without being chilled for up to one year, with the result that distribution and storage costs, as well as environmental impact, is greatly reduced and product shelf life expanded.

Layers of a tetra pak

Cartons for solid foods: Cartoning system can load the product through the end of the carton or fill the product vertically, and both of these may be performed as continuous processes. Cartons may also be supplied for systems which will erect, fill and close either a prelined carton or one which makes its own liner on the machine. Both these cartons can be used for vacuum or gas packaging at a speed of upto 60 or 70 cartons a minutes.

Seal and shrink packaging machine • Shrink tunnels using a heated air system, it used for shrinkable films (PE POF PVC) that have been applied by L-bar sealers, sleeve wrappers, and sealing cutters. Designed for high production, the air flow technology is used to circulate the air to avoid bubbles and bumps in . Independent control systems regulate temperature, air velocity and conveyor speeds, our shrink tunnels feature carefully controlled air velocity and temperature that are maintained throughout the tunnel for optimum film shrink. The efficient heating system on each machine reduces the amount of electricity needed to run the machine, consequently reducing operating costs. It is used to shrink pack goods, such as cans, glass bottles, mineral water etc., in wood, rolled steel, ceramics, household appliances, computers industries and more. • Shrink tunnels/Heat tunnels are designed to blow hot air onto film wrapped packages to make perfect shrink around packages. Shrink tunnels can be used to shrink a neck band or body sleeve around a container. Shrink tunnels are equipped with conveyor rollers, teflon net conveyor or belts to deliver product through . Packages must be shorter than the aperture height and less wide that the aperture width to fit in the shrink tunnel.

• is applied over or around the intended item, often by automated equipment. It is then heated by a heat gun or sent through a shrink tunnel or oven for shrinking. • Shrink wrap can be supplied in several forms. Flat roll stock can be wrapped around a product, often with heat sealing to tack the film together. Center folded film is supplied on a roll with the plastic is folded in half: product is placed in the centre portion, the remaining three edges are sealed to form a bag, and the package then heated which causes the bag to shrink and conform to the product placed in the bag. Pre-formed shrink bags plastic bags are used with one end open: the product is placed in the bag, sealed, and sent for heat shrinking. • Shrink wrap can be used to wrap buildings. It can wrap roofs after hurricanes, earthquakes, tornadoes and other disasters. Shrink wrap can be used for environmental containments to facilitate safe removal of asbestos, lead and other hazards. • Shrink wrap is commonly used as an on many types of packaging, including cartons, , beverage cans and loads. A variety of products may be enclosed in shrink wrap to stabilize the products, unitize them, keep them clean or add tamper resistance. It can be the primary covering for some foods such as cheese, meats, vegetables and plants. Heat-shrink tubing is used to seal electric wiring. Shrink bands are applied over parts of packages for tamper resistance or . It can also combine two packages or parts. • Shrink wrap is also commonly used within more industrial applications using a heavier weight shrink film. The principles remain the same with a heat shrinking process using a hand held heat gun.

Bottling A san be a collection of automatic machines connected by a conveyor belt or a group of highly specialized , fully automatic units completely integrated by a synchronised drive arrangement. Semi-automatic lines depend to a large extent on the dexterity of individual machine operators for their maximum output, an operating speed on these vary from 30 to 60 units per minute. For speed above this, highly automated machines are required Bottling processes are as follows: 1. Bottle feeding 2. Bottle cleaning 3. Filling 4. Closing 5. Labelling 6. Collating and packing for transport

Bottle feeding: apart from specialized operators such as dairies, breweries and a decreasing number of carbonated soft drinks manufacturers who use de-crating machines for removing incoming bottles from metal, plastic or wooden crated, many bottlers arrange with their glass manufacturers and fibre board providers for their new glass wares to be packed. Once the filled cases have been inverted and the bottles pushed onto a moving belt, they are conveyed away, a line at a time, to the main slat chain conveyor. Bottle cleaning: the traditional method of cleaning glassare is to wash it on one range of bottle washers available, and such washers re used extensively in dairies, breweries and allied industries using returnable bottles. However, where one trip bottles are used, a much simpler means is utilized for cleaning, compressed air. Conditions under which the bottles are stored, humidity or temperature variations may create condensation, causing dust to adhere to the container wall and thus nullify the air cleaning prosess, 60 psi is the minimum air presuure for efficient cleaning, and instrument quality air, free from oil and water vapor is essential. Filling liquid: filling machines for putting liquids into bottles can be divided into four basic types: vacuum-filling, measured-dosing, gravity-filling, and pressure-filling. It is shown in the table 4.1. Filling dry goods: there are two methods of filling powders and granules into . These are volumetric filling and filling after weighing. • Volumetric filling: the main methods are filling by auger, flaks and cups or vacuum filling. In auger filling, an auger is fitted into a sleeve mounted below a hopper containing, which should be granular and not too powdery. • Cup or flak fillers can handle powders as well as granular materials. A flask of known and adjustable volume accepts the product from a supply hopper, and when brim-full the supply cuts off and the flask discharges its content down a suitably designed chute. • The vacuum filling method is essentially similar whether liquids, powders or granules are filled. The containers are raised to th filling head, making a vacuum tight seal.

REFERENCES 1. PAINE F.A. AND PAINE HY, A HANDBOOK OF FOOD PACKGING, 1992