BULKPACK

Full automatic butter filling and packaging plant

BULKPACK – accurate filling and safe packing

The full automatic filling and packaging plant is designed

for butter, vegetable oil products and other pasty food stuffs.

The solid stainless steel construction assures a long-life cycle

even in continuous operation.

Progressive safety installations and latest servo-mechanism

ensure a smooth operational procedure and product handling.

Safety

■ closed stainless steel framework

(AISI 304) with safety covers■ integrated safety concept at all accesses■ polycarbonate cover panels for safe

monitoring of process

Technology

■ direct feed from butter pump – no compensating

piston required (no dead ends)■ each station is self-contained, both control wise and

electropneumatically, therefore each station may be

independently operated■ due to modular design the unit is already complete

wired and pretested prior delivery to minimize

commissioning time■ motor driven roller foil delivery, thus a smooth

constant winding can be guaranteed regardless

of the roll diameter, as well as exact foil length

Hygiene

■ interior easy to clean■ all parts coming in contact with product are of stainless

steel (AISI 316L) or food grade plastic material■ conveyor belt and drive motor optimized for use

in typical dairy operation (open, washable,

protection level IP 67)■ full automatic CIP-function for all parts in contact with

product inclusive filling head from inside and outside

Options

■ consistent modular build system – up to 5 modules

may be operated in parallel (up to 20 t/h), system can

be expanded easily in the future■ filling weights range of 10 to 25 kg possible,

change over-time < 10 minutes■ filling modules available with integrated foil

delivery or with external bag-in-box-insert machine

BULKPACK – proven, effective in practice and tested

Erected cartons are conveyed to and perfectly filled cartons

are released of the system. In-between the filling module

takes care of precise dosing and filling of pasty food stuffs.

BULKPACK

butter filling and packaging plant

BULKPACK

The complete line consists of the carton erector, the filling

head and the box sealer. A metal detector after the box

sealer can be optionally integrated the line.

Full automatic CIP

A cleaning container is just placed at the filling position to

clean the station and the filling head from inside and out-

side. Feed and CIP-return are connected to the system and

all product contact surfaces are full automatically cleaned.

Scale 2 /Fine dosingOutlet conveyor

Inlet conveyor

Electronic connection Air connection Foil roll

Scale1

Filling

Free position

Cleaningfeed

Cleaningreturn

How does it work?

The conveyor belt carries the erected carton to scale 1 on

which the tare weight of each single carton is measured

before filling. At the following filling position the foil

(if fitted with an integrated foil system) is cut and folded

around the filling head, the filling head drives with the

foil into the carton. The product, e.g. butter is pumped

through the filling pipe into the carton.

The filling head is “floating” on the delivered product and

in consequence of this lifted upwards to a defined position,

supported by adjustable pressurized pneumatic cylinders.

The filling valve is closed and the filling head moves out of

the carton. The filled carton is conveyed to scale 2 through a

free position. The net weight is calculated here (deduction of

the tare weight measured previously). The fine dosing then

automatically adds the difference to the required weight

(set point). A defined quantity of butter is pressed through

a small filling pipe into the carton. An electrical heated wire

cuts the butter in small pieces. Finally the outlet conveyor

belt moves the precisely filled carton out of the unit.

butter filling and packaging plant

Standard Equipment

■ filling module in a rack■ tare scale, gross scale■ fine dosing device■ conveyor belt for feed in of cartons (length 2,000 mm)■ conveyor belt for discharge of cartons (length 2,000 mm)■ CIP equipment for BULKPACK■ electrical control■ pneumatical control

Supplementary Equipment

■ foil cut and folding device■ final foil folding and closing device■ additional set-points for different weights■ statistical evaluation■ automatic sampling device■ foil printing■ carton printing

Production data evaluation PDASFILL

The optional available statistical evaluation and reporting

program PDASFILL allows to collect the production data in

convenient and secure manner. The statistic program runs on

a normal PC, integrated within a network. All weight data of

each carton is collected and transferred into an Excel sheet.

All analysis and diagrams may be adjusted to your require-

ments. The available option PDASFILL provides a significant

contribution to the quality management of your production.

Technical dataCarton dimensions 390 x 290 x 100 … 250 mm (outside dimension L x W x H in mm)

Filling weight 10 ... 25 kg

Filling accuracy < +/- 5 g (standard deviation)

Capacity 4,000 kg/h, per filling head, max. 20 t/h (5 filling heads) at 25 kg filling

Electrical connection

total connected power: 1 kW

voltage: 230 V, 50 Hz, 1 phase, N, PE

min. fuse: 25 A, cut-off characteristic C

Pneumatical connection

connection: pipe G 3/4“

consumption: 330 Nl per carton

pressure: min. 7 bar

Product connection DN 125, 5“, Tri-Clamp

CIP connectionfeed (max. 2 bar): DN 50, 2“, Tri-Clamp

return: DN 100, 4“, Tri-Clamp

Measurements and weight

total lenght: 3,325 mm (each additional module + 2,000 mm)

total width: 2,235 mm (with foil insert 2,780 mm)

total height: 4,050 mm (filling head erected)

height of conveyor belt: 700 mm

weight: 980 kg

BULKPACK

The ideal feeding station for the BULKPACK line

The feeding module for the BULKPACK line is the

automatic carton erector. The cardboard boxes are

taken from the magazine (flat packed), rectangular

erected and the folded bottom flap is closed with

tape and transferred to the filling unit – completely

full automatically.

Technology

■ electrical system for precise rectangular

erection (squaring) of carton■ tape monitoring system■ easy and quick adaptation to different formats

Safety

■ closed stainless steel framework (AISI 304)

with safety covers

■ integrated safety concept at all accesses■ polycarbonate cover panels for safe

monitoring of process

Technical dataCarton dimensions 390 x 290 x 100 … 250 mm (outside dimension L x W x H in mm)

Capacity up to 15 cartons per minute

Cardboard magazine horizontal integrated magazine, lenght 1,000 mm (optional 1,500 or 2,000 mm)

Transport side mounted conveyor belts for cardboard transport

Tapesystem Device suitable for up to 50 mm wide tape and 350 mm diameter rolls. Open tape feed path ensures easy replacement of rolls.

Alarms tape roll low, out of tape, no adhesion of tape, out of cardboard

Elektrical connection voltage, min. fuse: 400 V, 50 Hz, 3 phases, N, PE, 10 A

Pneumatical connectionconnection: pipe G 1/4“

consumption, pressure: 15 Nl per carton, min. 6 bar

Measurements and weight

total lenght: 2,870 mm

total width: 1,330 mm

total height: 1,560 mm

weight: 990 kg

carton erector

BULKPACK

To complete the line: Releasing of boxes

The full automatic case sealer takes over the boxes from the

filling module. The machine opens the top flaps, folds the

foil, presses the butter surface, closes the carton and seals it

with tape.

Hygiene

■ interior easy to clean

Technology

■ tape monitoring system■ easy and quick adaptation to different formats

Safety

■ closed stainless steel framework (AISI 304)

with safety covers■ integrated safety concept at all accesses■ polycarbonate cover panels for safe

monitoring of the process ■ drive motors and conveyor belts in

low-wear construction

Technical dataCarton dimensions 390 x 290 x 100 … 250 mm (outside dimension L x W x H in mm)

Capacity up to 10 or 15 cartons per minute (depending on model)

Transport side mounted conveyor belts for cardboard transport

Tapesystem Device suitable for up to 50 mm wide tape and 350 mm diameter rolls. Open tape feed path ensures easy replacement of rolls.

Alarms Tape roll low, out of tape, no adhesion of tape, out of cardboard

Elektrical connection voltage, min. fuse: 400 V, 50 Hz, 3 phases, N, PE, 10 A

Pneumatical connectionconnection: pipe G 1/4“

consumption, pressure: 5 Nl per carton, min. 6 bar

Measurements and weight

total lenght: 1,900 mm or 2,550 mm

total width: 1,200 mm

total height: 1,950 mm

weight: 900 kg or 1,150 kg

case sealer

BULKPACK

Catches, what is not part of the foodstuff

The metal detector detects metal-like impurities in foodstuff

by means of inductive sensors. All magnetic and non-

magnetic particles from the size of 3 mm of stainless steel

and 2 mm of ferrous are detected. Identified particles are

acoustically signaled and the conveyors belt is stopped.

Technology

■ closed stainless steel framework (AISI 304)■ high sensitive detector technique for

greater reliability■ integrated control system with individual

programmable outputs■ comfortable touch screen with illuminated

color display (5,4 inch)

Safety according to HACCP

■ regular request for performance test by operator

is displayed■ all Data is recorded and stored automatically

Option

Software for PC with following functions:

■ network of metal detector with PC■ automated data storage of all production data

and report according to HACCP directive■ check of metal detector and display of status

(metal detection, number, parameter)

Technical dataCarton dimensions 390 x 290 x 100 … 250 mm (outside dimension L x W x H in mm)

Smallest detectablepiece of metal

Stainless steel approx. 3 mm, iron approx. 2 mm, depending on product, moisture and salt content. Please note: cardborad material must be free of metal!

Transport horizontal conveyor belt for transport of boxes

Product temperature -20 to +60 °C

Diagnostic integrated software for diagnostic, automatic self-testing

Elektrical connection voltage, min. fuse: 400 V, 50 Hz, 3 phases, N, PE, 10 A

Measurements and weight

total lenght: 1,840 mm

total width: 920 mm

total height: 1,100 mm

weight: 250 kg

metal detector

All details of the products provided in this brochure are to be understood for information only without any obligation. Product range and models are subject to modification due to continual development. Liability for any incorrect or incomplete specification in this document is expressly excluded. Binding specifications, particularly of performance data and applicability for dedicated operation purpose, can only be made in the context of precise inquiries. Fo

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WAL Mess- und Regelsysteme GmbH

Ehnkenweg 13, 26125 Oldenburg, Germany

Fon +49 (0)441.9 33 66-0, Fax +49 (0)441.9 33 66-33

info@wal-ol.de, www.wal-ol.de