palletless packaging lines - maschinenfabrik mö · pdf filepalletless packaging lines...

Palletlessreverse hood

packages– the cost saving

transport unit

PalletlessPackaging Linesusing the Möllers reverse hoodstretch / shrink wrapping system

Palletlesspackaging

MACHINES • PLANTS • SYSTEMS

– 2 – Palletless packaging lines from Möllers

Filling, palletizing, packaging, loading.The entire process from a single source . . .

MASCHINES • PLANTS • SYSTEMS

New era of an innovative technology

It started with a visionary idea - eliminatingthe transport pallet by using the goods themselves as the load platform – the ideaof the self-supporting despatch unit, robustly braced within a sealed enclosure of shrinkfilm. Möllers engineers developed the reverse hood shrink system, and brought thenew technology to market.

The reverse hood shrink wrap load has proved its worth in countless installations incountries all around the world, proving itselfsuperior to conventional pallet loading. because the pallet has disadvantages – highcost, space requirements, no protection forthe cargo.

There was still one unfulfilled wish – a challenge which Möllers has successfullymet with the palletless reverse hood stretch-wrapped package, a robust load unitwith decisive new economic advantages.

The palletless despatch unit – now a choice between:STRETCH- or SHRINK-wrapped !

Palletlesspackaging

– 3 –

��

�

The transport pallet has undoubtedly becomean indispensable element in rationalizing thesupply chain and distributing goods efficiently.But the pallet is a costly logistics tool. Whetherthey are disposable pallets or a reusable ones,pooled pallets or your own, the procurementcosts are high. Then there are significant costsfor transporting and storing empty pallets.Inventory managmentand pallet repairs involve additionalcost, which is oftensignificant.

The functionality of pallets is also limited in extent;when pallet loads have to be ruggedized fortransport and protected against the elements, additional means such as stretch and shrinkhoods have to be used. They also reduce the effective payload by their own weight and volume.The palletless reverse hood despatch unit is the

superior alternative inmany applications, withadvantages extendingwell beyond substantialcost savings.

. . . with all components: Plant engineering

Eliminating pallet costs is a major saving, but not the only one:

The palletless reverse hood package has multiple benefits – for both consignor and consignee

Palletless packaging lines from Möllers

THE PALLETLESS DESPATCH UNIT

using the

REVERSE HOOD STRETCH / SHRINK

SYSTEM

A bundle of benefits: Eliminates all pallet costsRuggedized transport loads Watertight packaging for outside storage Product protected against dirt and theft Environment-friendly recyclable packageNow plus: energy and film consumption greatly reduced, plant throughput increased Maximum efficiency

– 4 –

Film applicatorStep 2: Place the base

strengthening films



The ultimate in reverse hood technology

New advantages of the palletless stretch-wrapped load

The energy-saving palletless stretch-wrappedload, produced without the application ofheat, is the ultimate in reverse hood packaging technology development. The highly stretchable Hi-Expander and Ultrastretch films provide high strength forthe self-supporting packages. The reversehood stretch-wrapped package combinesthe functions of wrapping and protectingcargo. This also includes protection againstmoisture ingress, contamination and theft.

The plant technology is mature and reliable,with the HSA-Vario at its heart: The gussetedtubular film is supplied from a reel and reefed onto the four nested stretch fingers,sealed to a hood along the required length,separated from the tubular film, then stret-ched to the wrapping width, and drawnover the stack covered with the base films.When the load has been turned, the reversehood is wrapped in the same way.

The function of the base films is to carry theweight of the package contents and to protect with their high break through strengththe package base.

1. Goods stacked. Last layer(top layer) in a reduced

stacking pattern

2. Base film applied 3. Inner hood drawninto position

4. Load turned through 180°The top layer now forms the

base of the load

5. Reverse hood drawninto position. Load is ready

for despatch

There are five steps in the production of a palletless stretch package


Palletlesspackaging

The base film applicator (left) covers the top layer of thestack with the base strengthening films. The load pressing and turning station grips the cargo stack bet-ween two conveyor belts, and turns it through180° ontoits base

The base film applicator, automatic stretch hooder andload turning station form the basic unit of the line

Step 1: Stack comesfrom automatic

palletizer

HSA-Vario transverse stretch hooderStep 3: Wrap inner hood

Step 5: Wrap reverse hood

Load pressingand turning stationStep 4: Upturn load

onto its base

THE DOUBLECLAMP

STRETCH

– 5 –

1

3

2

4

� ... rugged for shipping by road, rail or sea� ... ideal for bags and other containers, � ... even for high loads and heavy weights� ... suitable for transport on open vehicles, with

fast loading and unloading� ... storable outdoors in all weathers,� ... even at the consignee (customer benefit that

can be marketed by the supplier) . . . � ... optimized for minimum film consumption � ... made of environment-friendly recyclable material

Flexible in use, secure investment

� Reverse hood stretch packaging lines can handle loads of the most diverse types and formats.

� Reverse hood stretch packaging lines can alsobe used to produce normal unsecured pallet loads and stretch hood pallet loads.

� The range includes units with a throughput capacity of 40 to 100 loads per hour.

This flexibility in use and the cost advantages of thepalletless stretch load makes acquiring a reversehood stretch line a well founded, future-proof investmentthat soon pays for itself. Beside the conveyors andthe automatic palletizers needed to stack the product,the basic palletless packaging configuration comprises just three machine units: the HSA automatictransverse stretch hooder, the film base applicator,and the load pressing and turning station.

5-bag pattern with 4-bag chimney base layer

5-bag pattern with 4-bag base layer


4-bag chimney patternwith 3-bag base layer


10-bag pattern with 6-bag double base layer


Palletless reverse hoodpackaging is the optimum form of

transport packaging formany stackable goods.

Various stacking patterns can be used,

depending on the loadformat, e.g. for bags

The basic stretch packaging line PSH-1 is equipped with one automaticstretch wrapping machine, with a throughput of up to 40 units per hour

. . . with all components:

Filling

Roto-Packers and in-line packers forpaper and plastic valve bags

Reverse hood stretch loads are ….

Processing the stretch film hood1 Reef the hood onto the stretch fingers2 Stretch the hood to fit over the load3 Start to wrap the hood4 Understretch the stack

Patent pending:EP 2 036 818 A1

– 6 –



1. Goods stacked. Lastlayer (top layer) with reduced pack pattern

2. Inner hood drawn into position

3. Fork niches profiled on both sides of the

top layer

4. Load turned 180".The top layer now formsthe base of the package

5. Reverse hood drawn over

6. Fork niches reformed.The unit is ready

for shipping


Palletlesspackaging

Six steps to prepare a palletless shrink-wrapped load for shipping

The mother of all palletless film wrapped loads:

Maximum freedom of choice withthe reverse hood shrink package

With more than 200 Möllers reverse hoodshrink-wrapping lines installed and millionsof palletless packages moving securely byroad, rail and sea – the palletless shrink-wrapped load has been making history forthree decades. Its success is due to its robustness, its multiple load protection, itsadaptability and its reliable production process:

Stack the goods with a reduced top layer, wrap the inner hood, form recesses on bothsides of the top layer. Upturn the load ontoits base. Wrap the reverse hood, and reformthe fork recesses – for secure handling by forklifts and cranes. Load unit is ready to go !

Above: The PKS-1 shrink packaging unit is equippedwith a Combi-FSA automatic tubular film wrappingmachine with integral shrink frame

Below: High-performance shrink-packaging line PKS 2-HL for 90 loads per hour, equipped with two film wrapping machines and two separate shrink frames

THE DOUBLECLAMP

SHRINK

Step 1: Stack comes fromautomatic palletizer

Combi-FSA shrink wrapping machineStep 2 + 3: Wrap inner hood, shrink

hood and profile nichesStep 5 + 6: Wrap reverse hood, shrink

hood and reform niches

Load pressingand turning station

Step 4: Upturn load ontoits base

– 7 –

1 2 3

Both the length of the reverse hood and the film thickness provide effectivemeans of influencing film consumption and strength of the unit load.With additional base reinforcement, the reverse hood shrink-wrapped loadconstitutes an excellent packaging system, even in extreme applications


Full length reverse hood

Variable lengthreverse hood

Reverse hood as cover hood

Base bracing with bottom hood

Base bracing with bottom sheet

Base bracing with intermediate sheet

Base bracing withstacking plate

Cover made offlat film sheet

Standard package designs - material saving variants

Package designs with reinforced bases

Above: 1 Wrapping the inner shrink hood over the load2 Forming the fork niches in the inner hood3 Reforming the fork niches in the reverse hood

Tailor-made machines – flexible operation

� Möllers reverse hood shrink-wrapping lines are available with a capacity ranging from 20 to 90packages per hour.

� By combining various film thicknesses and loadcover formats with full-size or shortened reverse hoods, with a light cover sheet or with reinforcedbase, the system can flexibly adapt to different load weights and load stresses, whilst minimizingfilm consumption.

� Möllers reverse hood shrink-wrapping machines can produce normal pallet loads with or without shrink hood alternately, as well as palletless shrink-wrapped loads.

30 years of perfecting the technology

Since its introduction, the Möllers reverse hood shrink-wrapping process has always been marked bysignificant pioneering advances.

� Combi-FSA tubular film wrapping machine: Onecompact machine for film wrapping and shrinking.

� Controlled lamination of inner and reverse hood:Significantly strengthens the load cover

� Contra-laminar technology: Prevents the inner hood adhering to film-packed product.

� Security shrink frame: Satisfies the most rigorous safety standards of the chemicals industry.

� Energy consumption: Significantly reduced.

This history of pioneering development makes the palletless shrink-wrapped load one of the two high-grade options in the Möllers reverse hood system,alongside the palletless stretch-wrapped load – twotechnology options to choose from depending on thecriteria of your application.

. . . with all components:

Shrink-wrapping line PKS-1with integrated shrink frame

FFS bag filling machines, Pneumatic packers,Vacuum packers, Screw packers, Dumpweighers, Open-mouth bag filling lines

FillingDosingWeighing

– 8 –



Palletlesspackaging


Warehousing free of charge:

Reverse hood packages can be stored outdoors

The product is sealed tight in reverse hoodloads, excluding moisture. This eliminates theharmful effect of water and atmospheric humidity. This functionality soon earned the reverse hood wrapped load a second role, enabling product to be stored in the open. A flat surface is sufficient; there is no need toconstruct a storage building. This techniquehas been used in cement works for exampleto rapidly create additional storage capacity with negligible additional expense. Storing bagged cement in the open throughthe winter unharmed has convinced evensceptics of this additional benefit of the palletless reverse hood load unit.

Protecting product from dirt and contamina-tion is another function of the reverse hoodload; the sealed load also provides protection against pilferage. Producers usingpalletless reverse hood wrapping can leverage this welcome user benefit of outdoorstorage as a marketing tool.

The contents of a reverse hooded load are safe fromrain and snow

Reverse hooded loads with contents resistant to pressurecan be stacked two and more high, providing extensivestorage capacity

Open-air storage for reverse hooded loads is variable in size, pattern and position, and rapidly available as required

Store of bagged cement temporarilyestablished on unpaved surface at acement works in SouthEast Asia

– 9 –Palletless packaging lines from Möllers

Speedy loading of trucks and railcars:

Reverse hood unit loads get moving

. . . with all components: Automatic Palletizers

Palletizing

Reverse-hood packages are resistant to the rigours ofhandling and transport. The tough film cover robustlyencloses the goods, retains the shape of the load,and resists loading and unloading stresses. Thetightly sealed unit loads thus provide a further advantage of this unique type of packaging: reversehooded loads can be transported on open vehicles,since they are weather resistant. Open loading platforms of trucks and railcars are faster to access;many users have been pleased to find the new despatch units yield significantly reduced loadingand unloading times.

Open vehicles are well suited to transporting reverse-hooded packages, and ease of access speeds up loa-ding with forklifts and cranes. Loading from just oneside of the vehicle, with the forklift taking two loads ata time, makes for especially rapid loading

– 10 – Palletless packaging lines from Möllers

Reduced loading times cuts anchorage charges:

Reverse hood packages getsea freight going

Reverse hood shrink-wrapped loads haveproved the ideal form of sea freight. Compared to loading loose bags in slinghoists, they can achieve many times the loading and unloading rate with fully mechanized handling, thanks to their greater volume, precise, stowable shapewith high stack pressure resistance. Reducedloading times also cut port turnaround timesand demurrage charges. Reverse-hoodpackages increase the economic efficiencyof sea freight – not least because they eliminate the danger of bags bursting andthe consequent clearup time.

Reverse hood loads lend themselves well to stevedoring. They can be handledby crane using C hooks, double C hooks and shackle harnesses, and also inbelt slings, supporting cooperation between forklifts and cranes


Palletlesspackaging


With its excellent handling properties,the reverse hood package satisfies allthe requirements for rapid loadingand unloading of containers

– 11 –

Even after long and arduous journeys:

Reverse hood packages arrive in good shape


. . . with all components: Combi-FSA Shrink-wrapping machines

Shrinkwrapping

Sea voyages are not always gentle. But a well stowed cargo should be able to withstand roughseas. Reverse-hood packages satisfy this requirement,with all the features needed to arrive safe and sound– regardless of how often they are handled, themeans of transport and the distances involved.

Economicaland environment-friendly

Changing climatic conditions – cold and heat – haveno significant effect on the transport and storage characteristics of the unit loads. Transport and handling with no loss of product and without pollution provide economic and ecological benefits,which the palletless reverse-hood package combineswith the use of pollutant-free recyclable packagingmaterial.

After thousands of sea miles, the goods arriveat their port of destination in good shape,ready to be transhipped for onward transport,or to be stored temporarily outdoors

– 12 –




Palletlesspackaging

Möllers stretch-wrap packaging lines: The PSH range

Möllers reverse hood stretch-wrap packaginglines are available with nominal throughputrates ranging from 40 to 100 unit loads perhour. On the PSH-1 line the loads are turnedand then reversed to the automatic stretch-wrap-ping machine to wrap the reverse hood. The

PSH-K line has a bypass track for returning theload when the inner hood has been wrapped,the load is pressed and turned on this track.The PSH-2 line is equipped with two automaticstretch wrapping machines; the loads all passthrough the machine in the same direction.

PSH-1 stretch-packaging line Capacity: up to 40 units/h

PSH-K stretch-packaging line Capacity: up to 60 units/h

PSH-2 stretch-packaging line Capacity: up to 100 units/h

Crosswaysconveyor

Crosswaysconveyor

Bag flattening station

PLS automatic slideplate stacker

Base filmapplicator

HSA-Vario transversestretch hooder

Stack pressing andturning station

Package removalconveyor



Base filmapplicator


Stack pressing and turning station



Base filmapplicator



Stack pressing and turning station


– 13 –

Stretchwrapping


. . . with all components: HSA Stretch-wrapping machines

Möllers shrink-wrap packaging lines: The PKS range

Möllers reverse hood shrink-wrap packaginglines are available with nominal throughputrates ranging from 20 to 90 loads per hour.They can be operated with gas or electricallyheated shrink frames, the latter also in a special safety version. The PKS-1, PKS-K and

PKS-2 models are equipped with Combi-FSAautomatic film wrapping machines with integral shrink frame. The high-performancePKS-2 HL line uses two FSA automatic tubular filmwrapping machines, each connected to a separate shrink frame.

PKS-1 shrink-packaging line Capacity: up to 20 units/h - Electric heatingup to 25 units/h - Gas heating

PKS-K shrink-packaging line Capacity: up to 30 units/h - Electric heatingup to 40 units/h - Gas heating

PKS-2 shrink-packaging line Capacity: up to 40 units/h - Electric heatingup to 60 units/h - Gas heating




PFS automaticstacker

PLS automaticstacker

Crosswaysconveyor

Crosswaysconveyor



Shrink frame withniche profiler

Shrink frame withniche profiler

Combi shrinkwrapping machine with niche profilers




Tubular film wrapping machine

Tubular film wrapping machine








PKS-2 HL shrink-packaging line Capacity: up to 55 units/h - Electric heatingup to 90 units/h - Gas heating

– 14 –


.MACHINES • PLANTS • SYSTEMS


Palletlesspackaging

When a name is a benchmark:

The many features of Möllers quality

“It is the M of palletizers . . .“ –When world-class products acquirea reputation for excellence, they areoften quoted as a benchmark. Inthis context the letter M stands forMöllers of course, but sometimespeople like to replace our name by a German make of car which enjoys the worldwide highest reputation. We accept this marketassessment, since it is based onstrict adherence to a level of qualitythat certainly bears comparisonwith the premier league of Germanindustry. In all aspects of our work– in researching market needs, developing more efficient systems,designing and manufacturing ourproducts, and serving our customers– we aspire to excel. There are examples and features that testify to our consistent success in this endeavour.

Feature - Optimum drivedesign: the rack-and-pinion drive of thestretch arms on theHSA-Vario stretch hoo-der proved to be thebest solution: high effi-ciency, low mainten-ance, very quiet

Feature - Ease of maintenance: the drivesand control system valve clusters aregrouped at a readily accessible point tofacilitate access as required

Feature - Compact format: small footprintwith good accessibility istypical of Möllers plant.Even the double headvariant of the HSA-Variostretch wrapping machine for two types offilm only slightly exceedsthe compact depth of thestandard model

Feature - Quiet running:this feature contributes to

high plant availabilityand long service life,

and involves judiciousutilisation of machine

mass. Möllers machinesare mainly constructed ofsolid rolled steel sections

–15 –Palletless packaging lines from Möllers

Producat® keeps tight control of stretching and shrinking

For a clear overview of your packaging operation:

Producat® is the control and monitoring software developed by Möllers for managing the entire fillingand packing plant of any size from a central terminal.Producat®also supports linking to master systems (hostcomputers), and can be connected to company intranets via its Internet capability, so that order processing and plant diagnosis can also be handledfrom other authorized computers. Producat® runs on a standard PC networked to the machines’ PLCs. Producat® is structured in several program modules fordisplaying information and inputting commands.

Module A: Order processing

Module A enables production orders to be entered by accessing complete product data records in tabularform at the click of a mouse. All necessary machinesettings are made automatically without error.

Module B: Plant diagnosis

Module B provides parameter overviews and zoomable layout images displaying all actuators andsensors, to enable monitoring of plant operations.Faults are rapidly located by flashing or colour codingof the actuator / sensor signals.

Module C: Software maintenance

Module C is used for basic system settings and for online updating of system software via the Möllersteleservice, and for remote diagnosis via the Möllersteleservice as required.

In the graphic overviews of the plant diagnosis module, thesensors and actuators are displayed as coloured signals thatfacilitate fault location by colour coding or flashing

Order processing module: Complete product data recordscan be accessed at the click of a mouse, this way all necessary machine settings are activated automatically

Producat® acquires machine data at control level, and processes it for the data management level

. . . with all components: Service

Controlling Monitoring

Filling plants for bulk, liquid andpasty products

Palletizing plants

Palletizing and depalletizing robots

Stretch filmpackaging plants

Machines · Plants · SystemsPlanning, development and manufacture of complete plants

Everything from a single source

Maschinenfabrik Möllers GmbH · 59269 Beckum/Germany · Sudhoferweg 93-97 • 59247 Beckum/Germany · Postfach 1764Telephone +49 (0)2521 88-0 · Fax +49 (0)2521 88-100 · [email protected] · www.moellers.com

Manufacturing plants of the Möllers Group:

Mollers North America Inc.5215 – 52nd St. S.E., Grand Rapids, Michigan 49512 / USATelephone +1 (616) 9 42-65 04, Fax +1 616 9 42-88 [email protected], www.mollersna.com

GREIF-VELOX Maschinenfabrik GmbHP.O. Box 12 11 51, 23532 Lübeck / GermanyKronsforder Landstraße 177, 23560 Lübeck / GermanyTelephone +49 (0) 451 53 03-0, Fax +49 (0) 451 53 [email protected], www.greif-velox.de

Logdos Liquid FillingP.O. Box 12 11 51, 23532 Lübeck / GermanyKronsforder Landstraße 177, D-23560 Lübeck Telephone +49 (0) 451 53 03-0, Fax +49 (0) 451 53 [email protected], www.logdos.de

Librawerk Maschinenfabrik GmbHVossenkamp 1, 38104 Braunschweig / GermanyTelephone +49 (0) 531 370 98-0, Fax +49 (0) 531 370 [email protected], www.librawerk.de

NATRONAG Maschinenfabrik GmbHVossenkamp 1, 38104 Braunschweig / GermanyTelephone +49 (0) 531 370 98-0, Fax +49 (0) 531 370 [email protected], www.natronag.de

Subsidiaries of the Möllers Group:

000 „Möllers Intertec“, ul. Giljarowskogo, d 39, office 301-304Moscow / RussiaTelephone/Fax +7 495 780 97 [email protected]

Möllers Singapore, Singapore Representative Office, # 10 – 09 Golden Mile Tower6001, Beach Road, Singapore 199 589 / SingaporeTelephone +65 6 298 9860/9817 6880, Fax +65 6 298 9289 [email protected]

Möllers France, 14, rue de la Papeterie 67310 Wasselonne / FranceTelephone/Fax +33 3 88 87 29 00, Mobile +33 632 98 2452 [email protected]

Möllers (UK) Ltd., Maxron House, Green Lane, Romiley, StockportCheshire SK6 3JQ / Great BritainTelephone +44 161 406 9824, Fax +44 161 494 5982, [email protected]

Möllers Prague, Nad Rokoskou 14,18200 Praha 8 / Czech Republic Telephone +420 2 8468 2462, Fax +420 2 8468 0499, [email protected]

Möllers Brazil, Via Anhanguera km 14,5 - Vila Mangalot, 05000 São Paulo / Brazil

05.2

009/

2,0

E/Ry

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Fully automatictruck loading systems

Conveyorand loading systems

Controland visualizationsystems

Shrink filmpackaging plants

Palletlessshrink/stretchpackaging plants

Bag loading machines

Bag loading systems

FillingShrink-

wrappping Loading

PalletizingPalletlesspackaging Conveying

Stretch-wrapping Loading

ControllingMonitoring

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