OverviewTMCI GroupNEWPACK Division

Dairy CreamersForm-Fill-SealProduct Dosing SystemAseptic Version (ST)

MaterialsCup FilmLid Film Economic Analysis

Executive Summary

NEWPACK Global service about thermoforming, from engineering to after-sale service

MaterialsTechnical synergy with the suppliers in order to solve any kind of need granting best performances and paying attention to the costs

FFS for Dairy Creamers

Customisation and machines’ high level of efficiency

Cups Best attention to shape and design

OverviewTMCI GroupNEWPACK Division

Dairy CreamersForm-Fill-SealProduct Dosing SystemAseptic Version (ST)

MaterialsCup FilmLid Film Economic Analysis

TMCI Group

Osman SagmanliPresident & CEO

TMCI Group is a multinational company based in Switzerland and present with business units in Italy and Great Britain.

These business units grant a complete service all over the world in the following fields:wine, beer, soft drinks, oils and alimentary fats, bakery products, chocolate and jam, jellies and processing systems for fruits and vegetables.High level of ratio quality-price, client’s satisfaction, maximum flexibility, availability of complete lines which are part of the TMCI Group, a world-wide leader in his field.

TMCI PadovanLeader in the manufacturing of processing machines for wine, beer, tomato, fruit juices.

Turnover: 35 millions €Employees: 130 people

Certified ISO 9001:2000

New Plant of 12 thousands square metres in an area of 23 thousands square metres.

NEWPACK Division• This Division designs and manufactures complete lines for packaging

• In particular, Thermoforming machines in standard versions, also in ultraclean and aseptic versions

NEWPACK Division

Mission:To give high quality level customised solutions in order to help our customers present their products in the best way and thereby becoming more and more competitive.

OverviewTMCI GroupNEWPACK Division

Dairy CreamersForm-Fill-SealProduct Dosing SystemAseptic Version (ST)

MaterialsCup FilmLid Film Economic Analysis

Your productNEWPACK customises the cup’s shape together with the client in order to get it special.

Your FFS

Our care for...

- maximum flexibility for the adjustment of material’s heating temperature (which can be set on the touch-screen)- maximum care to the parts to be heated (by means of heating shaped plates)- sterilisation of punches and forming chamber by means of peroxide vapours; use of sterile moulding air in order to avoid contamination- maximum care during the cup forming phase in order to allow material’s homogeneous distribution by means of air-flow adjustment and mechanical punches’speed adjustment- mould’s shape realised with CAD/CAM 3D by a supplier of recognised professional experience

DATA CODER AND BRAND

Our care for...

- maximum flexibility in sealing plates heating temperature’ adjustment (which can be set on the touch-screen)- speed at the machine’s start by means of a bronze electrode with high thermal conductivity - maximum precision in centring the drawing on the cup’s lid thanks to the use of an automatic centring system controlled by a photocell which reads the guiding marks- maximum flexibility in welding plates pressure’s adjustment to allow the using of the most different covering materials (for example: aluminium, mixed-paper, metalisedPET, etc…)

Our care for...

- using of cutters with high resistance in steel K110- maximum flexibility in hydraulic cutting pressure’s adjustment in order to set the exact value and so improving the duration before it must be re-sharpened.- trimmers especially designed and manufactured, on the base of the material’s characteristics and thickness, by a supplier of recognised experience - (dairy creamers) possibility of using, without any problem, thickness from 0,6 mm up to 1,6 mm (upon request we can produce trimmers who can reach over 2,0 mm)

Our care for...

-careful choice of the best dosing system based on the different kind of products- (dairy creamers) using of a volumetric product control by means of calibrated chambers individually adjustable which assure a precision of ± 1%- tank in overpressure with sterile air, to avoid contamination and create a head which smoothly conveys the product through the feeding channels up to the cup- automatic program for CIP washing and SIP sterilisation in closed system. Thermostats for control, placed in correspondence of the circuit’s cold points, keep the temperature stable for the pre-set time.

Our care for...

HEATING Heating, drying, pre-sealing, sealing

STEAM Steam barriers placed on commands to avoid contamination

STERILE AIR Overpressure of the air to keep the environment sterilised

H2O2 Sterilisation of packaging materials by means of immersion

H2O2 VAPOURS H2O2 vapours are in-taken and conveyed outside

PRODUCT

ST: Care for the product

-NEWPACK thermoforming machines in aseptic version are equipped with an additional unit which allows the pre-sterilisation of both machine and installations and keeps the environment aseptic during all the production cycle.- pre-sterilisation is carried out through two separated circuits:1. Sterilisation of dosing unit and filters by means of steam for the following production of sterile air 2. Sterilisation of filling tunnel, punches, forming chamber and conveyors for the distribution of overpressure sterile air, by means of H2O2 vapours

Aseptic Version

- the last two phases of pre-sterilisation are the drying one and the cooling one at the end of which the machine gets sterilised and ready to produce.- all the phases are controlled and managed by the machine’s software which, by means of a touch screen panel, guides the operator preventing wrong operations or not exact processing sequences.- suitable alarms advise in case of machine’s wrong functioning and suggest what to do in order to go back to the optimal conditions.

Aseptic Version

-Packaging materials are sterilised during all the packaging cycle, before getting into the sterile area.- sterilisation is carried out by means of an immersion in a tank with H2O2 with a concentration of 35%.- drying devices such as mechanical squeeze rolls, blows of sterile air and sets of infrared lamps, grant the complete removal of H2O2 from the two films after sterilisation.

Aluminium lidwashing tank

Plastic web washing tank

Aseptic Version

-In order to keep steady the sterile conditions reached during the sterilisation, it has been foreseen an overpressure of sterile air from the heating station to the pre-sealing one.- in case of oxidisable products inert gases are used instead of sterile air - all the mechanical commands which are inside the machine’s aseptic tunnel are protected by means of steam barriers, the temperature of which is constantly controlled.- the films, before leaving the sterile area for the final sealing and cutting operations, are pre-sealed along the edges in order to isolate the product from the external environment.

Aseptic Version

- suction hoods are placed on the machine in correspondence of:1. Plastic web washing tank2. Heating and forming station3. Filling tunnel4. Aluminium lid washing tank- they convey the peroxide vapours out of the production areas.- the suction is carried out by means of an electric fun.

Aseptic Version

MaintenanceIn order to grant the maximum efficiency in time, it is necessary to take care of:

• WELDING PLATEwe suggest to control it has a good flatness

and that there are no materials on (with a machine tool it is possible to get back to the exact functioning adjusting the surface -operation suggested 1 time / year - anyway an additional electrode is always supplied)

• TRIMMERafter a while, depending on the material’s kind and thickness and his use, the cutters loose their efficiency (giving the trimmer to a specialised supplier, it is possible to re-sharpen the cutters - operation suggested 1 time / each 10 months if they work 8 hours a day, it means only 1 shift)Some companies consider the possibility of having an additional trimmer

• DOSING UNIT AND ASEPTIC EQUIPMENTseal and filters control (set of spare parts for dosing unit and aseptic unit are supplied according to the maintenance plan scheduled)

NEWPACK machines use:

• pneumatic

• hydraulic

• brushless motors

• industrial automation

Project development

FUNCTIONAL START-UP IN ITALY WITH TEST OF THE DIFFERENT MATERIALS’ KIND AND THICKNESSES

TELESERVICE VIA MODEM WHICH ALLOWS TO CONTROL IN ANY TIME THE MACHINE’S FUNCTIONING

DELIVERY OF THE MACHINE WITHIN 5 MONTHS FROM ORDER CONFIRMATION AND CUP DRAWING’S APPROVAL

INTERACTION WITH CLIENT DURING ALL THE PROYECTING PHASE, ESPECIALLY FOR THE CHOICE OF THE MATERIALS

OverviewTMCI GroupNEWPACK Division

Dairy CreamersForm-Fill-SealProduct Dosing SystemAseptic Version (ST)

MaterialsCup FilmLid Film Economic Analysis

the plastic cups filmPolystyrene based barrier plastic materials for cup:

-Medium Barrierapproximated costs 2,50 €/kg

-High Barrier

It is also possible to create coloured cups in order to better impress the final client.

the lid filmLid’s material in 3 alternatives:- ALUMINIUM- ALUMINIUM with PETindicative cost 12,00 € / kg- PET (less barrier effect)

Solution 10 ml