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Hermann WALDNER GmbH & Co. KG Anton-Waldner-Straße 10 – 16 Tel. +49 (0)7522 986-348 88239 Wangen im Allgäu Fax +49 (0)7522 986-419 Germany [email protected] www.waldner.de WALDNER Dosomat www.inallermunde.de Filling and Closing Machines Rotary and Inline Machines

Filling and Closing Machines - Dosomat · The WALDNER filling and closing machines are outstanding due ... The DOSOMAT rotary machine of the types 1, 2 ... • Weighing dosing systems

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Hermann WALDNER GmbH & Co. KG

Anton-Waldner-Straße 10 – 16 Tel. +49 (0)7522 986-34888239 Wangen im Allgäu Fax +49 (0)7522 986-419Germany [email protected] www.waldner.de

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Filling and Closing Machines Rotary and Inline Machines

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The WALDNER Group of Companies – A Powerful Trio

Today the WALDNER group of companies consists of the following individual branches:

•HermannWALDNERGmbH&Co.KG

•WALDNERLaboreinrichtungenGmbH&Co.KG

•WALDNERLabor-undSchuleinrichtungenGmbH

The quality of WALDNER has been setting standards – forawholecenturynow.Accordingtoourcustomers’requirementsweintensivelyuseourpotentialsandexceedthelimitsofourbusi-nessfields.Thus,thethreeWALDNERbranchesstandforstability,experienceandcontinuityreferringtotheirsizeandintegrationintothewholegroupofcompanies.

WALDNERDosomat

WALDNERLaboreinrichtungen

GmbH & Co. KG

WALDNER Labor- und Schul-

einrichtungen GmbH

Hermann WALDNER

GmbH & Co. KG

Dosomat Füll- und Verschließmaschinen

Process Systems

Wassertechnik

TheWALDNERfillingandclosingmachinesareoutstandingduetotheiradvancedtechnology,greatflexibility,enormouscapacityandabove-averageefficiency.

Themachinesaredesignedforanoutputrangebetween1.000 and100.000packagesperhour,dependingonthecustomer’srequirements.

TheDOSOMATrotarymachineofthetypes1,2,7,10,12aswellastheDOSOMAT16ASforthesterilefillingofsensitiveproductsareespeciallyappropriateforsmallandmidrangeoutputsandfortheuseofdifferenttypesofpackagesandcontainersizes.Duetotheergonomicquickreleasesystemthechange-overtoanothercuporlidformatcanbeachievedeasilyinafewminutes.

Forlargeroutputrangeswerecommendourhigh-performance inlinemachine,typeDOSOMAT20,whichisalsoavailableas an“AS”versionforthesterilefillingofhighqualityproducts.

AnothermemberoftheDOSOMATfamilyistheUNIMAT,afullyautomaticdosingunit,whichcanbeaccessorisedorfullyintegratedasanadditionalfillingunittoexistingclosingmachines(e.g.cuppingplants).

An overview of the range of machines:

•DOSOMATrotarymachine

•DOSOMAT inline machine

•DOSOMATASforsterilefilling

• End-of-linepackingmachines

InterpacGmbH & Co.

www.interpac.de

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Fullyautomaticcupfillingandclosingmachineforfillingavarietyofdifferentproducts intopre-madecups,whichmaybeofplastics,aluminium,carton,coex,tinorglass.Thefillingrangeextendsfromliquidstohighviscosity,powderyproductsorproducts withparticulates.Alsocosmeticandtechnicalproductsarepackedintopre-madecups.Theclosureofthecupsiseffectedbypre-madealuminiumfoils,snap-on-lidsorby sealingaplasticoraluminiumfilmfromrollstockwithintegratedcuttingunit. TheDOSOMATInlinemachinescoveranoutputrangebetween4.000–100.000packsperhour.

Machine design

Thebasicframeofthemachineisofamodularconstruction.Theframehousesthedrivinggroupsandthegearboxwhichareeasilyaccessible.Allproductleadingpartsaremadeofstainlesssteelorplasticssuitableforfood.

DOSOMAT20–Inline

Dosing systems

•Pistondosingsystems• Inductiveflowmeasuring•Massflowmeasuring•Weighingdosingsystems (e.g.forfruitormeatpieces, powdersetc.)•Pocketfillers(muesli,chunks)•Augerfillers•Roboticsystems/pick-and- placeoftechnicalarticles, etc.

Theappropriatedosingmethodisavailableforanyproduct.

Drive versions

•ServomotorviaELAU PacDrive•Frequency-controlledmotors•Mechanicaldrive•Pneumaticdrive•Orcombinationsofthese features

Thedrivetrainisbyservomotororbyfrecquency-con-trolledmotor-gear-combina-tions.Forthemaindrivethehightestpriorityisgiventosmoothaccelerationanddecelerationforanyproduct.

Closing Systems

•Heatsealing•Specialheatsealingfor aluminiumcups(sterilisable)•Hot-melt(cosmetics)•Snap-on-lidding,withor withouttamper-proofclosure•Ultrasonicsealing• Inductivesealing•Sealingfromrollstockand lid-cutting•Sealingfromrollstockwith integratedlidcutting

DOSOMAT 20.10 AS incl.sterilisationofpackagingmaterial

Capacity:25.000cups/hour Theintegratedcase packeroftheDOSOMAT20inlineassembles,accordingtothepackagingarrangement,thecupsfromtheslatconveyorandplacesthemintothepre-madecartonortray.

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Fully automatic case packer

Theintegratedcasepackertakesthecollationofsinglecupsandstacksthemautomaticallyintothepre-erectedcartons.

This machine is equipped with a sealing from rollstock including print registration

Thesealingfilmisunwound,adjustedbymeansoftheregistrationmarksandsealedtothetray.Inthefurtherprocesslongitudinalandtraverseknivescutoutthesingle-portioncupswithoutleavingresidualmaterial.

DOSOMAT20–Compact

Fields of application are: Dressings

Thismachineisprimarilyusedforfillingdressings,mayon-naiseorsimilarproductsintosingle-portioncups.Capacity:10.000–40.000cups/hour

Thesingle-portioncupsaredestackedintoatraywith24cells,insertedintotheDOSOMATmachine,filledwithproduct,separatedandfinallypackedincartons.

DOSOMAT 20.24 CompactWithintegratedcasepacker

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ThedelicatessenindustrytrustsinWALDNERDOSOMATmachineswhenitcomestothecarefulfillingandpackingofsaladsorsimilarproducts.Inthiscasethefillingrangeextendsfromsingle-portioncupsuptolargebins,whichcanbefilledwithherringsalad,shrimpsalad,beansalad,coleslaw,potatosaladetc.

DOSOMAT20–Delicatessen

Lid magazine/lid setter

Thepre-madeandembossedsealinglidsaretakenfromthemagazineviavacuumsuckersandplacedontothecups.

Thedestackingofthelidsiseffectedbymeansofspecialscrolls,inordertoguaranteeacorrectseparation.Automaticlidscan on missinglid=machinestopsanddisplaysfaultmessage.

Cup feed:

Thecupsetterisloadedfromthelinearbuffermagazine,inastand-aloneversionorintegratedonthemachine,from a cup carousel or from an alternativestoragemagazinespecifiedbythecustomer.

Dependingonthecupmaterialupto1.500cupsperlanecanbestoredinthelinearmaga-zine.Therecupsarefedinstackstothecupsetter.Thesystemassuresanoptimalbuffertimedependantonthemachinespeed.

DOSOMAT 20.6Fillingof1kgcupswithtamper-proofsnap-on-lidsCapacity:16.000cups/hour

Fields of application are: delicatessen

Hygienicdesignandfullflexibilityarethemainrequirementsofthedelicatessenindustry.

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WALDNERDOSOMATmachinesarethemarketleadersintheinnovativefillingandpackingofPaté,meat-spread,liversausageetc.intoplasticcupswithre-closablelids.Engineering,constructionandserviceofthemachinesaregivenspecialattentionbyWALDNER.Duetoperfectqualityassurancesystemscanbetracedbackandhencethehighestqualitylevelbecomesastandardfeature.

DOSOMAT20–Paté,LuncheonMeat

Sealing unit from rollstock

Withintegratedsealing-/cuttingunitforsealingandcuttingthefilmsimultaneously,including rewinding of skeletalwaste.Aservodrivensealingstationisincluded.Aspecialsealingheadmaterialwithsimilar

propertiestothatoftheconductivityofcopperandresilienceofstainlesssteelisusedinordertoachieveminimumtemperaturefluctuationsandabalancedtemperaturelevelpluslonglife.

Theproductisconveyedtothedosingunitbyvacuumfillerincludingcompensationcylinderandfilledintothecupsthroughaprovenpistondosingsystem,whichincludesaspeciallydesignedrotarycutter.

Inordertoobtainaminimumcontentofresidualoxygenitispossibletoequipthemachinewithaclosedchamberforevacuatingthecupheadspaceandforasubsequentflushofprotectivegas.

DOSOMAT 20.5 withsealingfromrollstock,cupevacuationandgasflushingwithresidualoxygencontentof≤0,3%

Thecupsaredestackedfromthemagazinebyamechanicallydrivenscrollsystemwhichguaranteesperfectdestackingwithaminiumoffaults.

Thecupsarestabilisedanddrawnintothecupslatwithvacuumassistance.Automaticcupcheck:onmissingcup,themachinestopsanddisplaysafaultmessage.

Cup setter with control unit

Fields of application are: Paté, Luncheon Meat

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Fields of application are: dairy products

FortheDOSOMAT20ASmachinethecupsandlidsaresterilisedwiththemostadvancedtechnology.Thesubsequentstationsarecovered,hermeticallysealedandflushedwithsterileairsoastoavoidanyrecontaminationofthepackaging.

DOSOMAT20AS–WithSterilisationofPackagingMaterial

Cup sterilisation

ThesterilisingagenthydrogenperoxideH202issprayedthroughspeciallymanufac-turednozzles.Theatomisedcleaningagentismixedwithaflowofhotsterileairandblownintothecupsviadeliverynozzles.Thisprocessensuresgoodsprayingofthecupswithoutformingdrops,whileanoptimalreactivetemperatureisreached.Thecupsaredriedwithhotsterileaironthefollowingmachinestations.

TheairloadedwithH202 is dischargedexternallyandsafelyawayfromthebuild-ing.Allcleaningmediaarecompletelypreparedinaseparatemodule.

Exactcontrolanddosingofallcomponentsguaranteeoptimaldegerminationrates,whilethemachinesurround-ingswillbelargelyfreeofcontaminationthroughthesterilisingagents.

CIP cleaning / SIP sterilisation

Execution:Thisversionincludesaclosedhopperwithsprayballandelectriclevelcontrol.Theentiredosingunitcanbecleanedinplacewithoutdismantling.Toinitiatethecleaniningprocedure,thecircuitisclosedbymeansofanautomaticlockingcleaningadapter.

Allcomponentsandsealsmeettherequirementsforfoodproductsandcanbeadjusted

tothespecificrequirementsatthecustomer'slocation(3A,EHEDG).TheWALDNERstandardwhichappliestoallCIP/SIPrelevantpartsavoidsdeadlegsandotherpointsofcontamination.Thesterilisationprocedureofthedosingunitiscontrolledthroughsafetychecks(timeandtemperature).Thismeansthatthedosingunitisonlyreturnedtoproduction,whencleaningandsterilisationissuccessfullyachieved.

Lid sterilisation

The aluminium film lids are takenfromthelidmagazine,sterilisedwithstrongultravio-letradiationandplacedonthefilledcups.Forthissterili-sationnon-ozonicprojectorsareused.Asophisticatedaerationsystemusingsterileairallowstheuseofevenplasticfilmlidsonthemachine.

Optionally,infraredorH202 systemsareavailableforsterilisation.

ThesubsequentstationsofDOSOMAT20Inlinearecov-ered,hermeticallysealedandflushedwithsterileairsoastoavoidanyrecontaminationofthelids.

DOSOMAT 20 ASforfillingyoghurtinto1kgbucketsCapacity:9.000cups/hour

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TheDOSOMAT1Compactmachineisarobust,easytohandle,fullyautomaticcupfillingandclosingmachinewhichistheidealsolutionforsmallandmediumcapacities.ThebasicversionisbasedontheexecutionoftheprovenDOSOMATmachine,type1.Themechanicalspeedreaches50cycles/minute.However,theactualspeedofthemachinedependsontheproduct,volume,cupsizeandcupheadspace.

DOSOMAT1.1Compact

Thismachineisappropriateforpre-made,stackablecupswithamaximalformatdiameterof125mmforroundcupsand130x90mmincaseofrectan-gularcups.

Theclosurecanbeeffectedbysealinganaluminiumfilmlid,asnap-on-lidorcombinationsoftheselidtypes.

DOSOMATrotarymachinesareadequateforanoutputrangeof2.500–30.000cups/hour.Theyareappropriateforfillingliquids,highviscosityandpowderyproductsorproductswithparticulates.

DOSOMAT1–RotaryMachines

DOSOMAT 1Rotarymachinefor1–4laneswithlaminarairflowcabinet.Capacity:2.500–10.000cups/hour

Quickchange-overtoan-othercupformatisachievedbysimplychangingthecupmagazine.

Anewquick-releasesystemofcupcellswithintherotarytableforasimpletoolessformatchange.Sealingstationwithquick-actionclosurecanbefoldedupwards,againtooless.Appropriatefortwodifferentcupdiameters,exchangeofthesealingplateisnotnecessary.

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DOSOMATmachinesarebasedonthelatesttechnologyandconstantdevelopment.Thequalityofourproducts,anexcellentmanufacturingknow-howandtheflexibilitytomeetthecustomers’requirementsthroughindividualsolutionsarethebasicprinciplesofoursuccess.

DOSOMATRotaryMachines

•Dosingsystemswithout dirttraps•Hose-downexecution•OptimizedCIP/SIPsystems•Laminarairflowcabinetin pharmaceuticalexecution

•Sterilisationofpackaging materialstothelateststate ofart•Energyconduits(forair, power,water)areled throughthecornerpillars

DOSOMAT7

DOSOMAT 7Rotarymachinefor1–6lanesCapacity:2.500–15.000cups/hour

Carriage for format parts

Outstandingfeaturesare:

•Quickchange-overto anothercupsize•Thepossibilitytoruna varietyofdifferentcups•Simpleandelegant operation

•Easycleaning(compli- ancewithHACCP-/EHEDG) throughaself-draining design and a minimum ofmovementsthrough themachinetable.

Simple change of cups through quick-release format parts

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Thefollowingexamplesshowsomeproductsthatcanbefilled:naturalandfruityoghurt,yoghurtwithmuesli,cream,quark,freshcheeseandprocessedcheese;avarietyofsalads,soupandsaucepaste,dressings,mayonnaise,mustard,butter,margarine,spreads,honey,jam,patés,petfood,cosmeticcreams,gels…

DOSOMATRotaryMachines

Dosing systems: •Pistondosingsystems• Inductiveflowmeasuring•Massflowmeter•Weighingdosingsystems (e.g.forfruitormeatpieces, powders,etc.)

•Pocketfillers(muesli,chunks)•Augerfillers•Roboticsystems/pick-and- placeoftechnicalarticles

DOSOMAT10

Theappropriatefillingvalvesareavailableforanyproduct,e.g.aspecialrotarycutterforstringypetfood,ortappetvalvesforveryliquidandthinproducts.

AlmostallfillingunitsareavailableinCIP/SIP.

Available in different variations with:

•Pneumaticdrive•Mechanicaldrive•Servomotor•Frequency-controlledmotors•Orcombinationsofthese features

Sealing from rollstock

DOSOMAT 10Rotarymachinefor2–8laneswithsealingfromrollstockandlaminarairflowcabinetCapacity:5.000–20.000cups/hour

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DOSOMAT12DOSOMATRotaryMachines

Packaging material

WidelydifferingpackagingmaterialscanbehandledbytheDOSOMATmachines:thecupsorlidsmaybeofpaper,plastic,coex,aluminium,tinorglass.

Discharge of closed cups:

Thecupsareliftedoutofthecupcellsandpushedontoabeltconveyorrespectivelytransferredtoasubsequentmachineortoanintegratedend-of-linepackagingunit.

Integrated case packer

ThecasepackerwhichisintegratedintheDOSOMATmachine,takes,accordingtothepackagingarrangements,thecupsoutofthecupcellsandplacesthemintothepre-madecartonortray.

DOSOMAT 12Highperformancemachinefor2–12laneswithlaminarairflowcabinetCapacity:5.000–30.000cups/hour

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TheDOSOMAT16ASmachinesaresuitableforfillingcupsandbucketsandutilisesofanintegratedsystemforsterilisationofthepackagingmaterial.Capacitydependingonmachineversion:3.000–15.000cupsperhour.

DOSOMAT16AS–RotaryMachineWithSterilisationofPackagingMaterial

Requirement profile:

Accuratefeedingsystems,cleanroomtechnology,sterilisationofpackagingmaterial,precisedosingunits,reliableclosingtechnology.

Fields of application:

•Dairyindustry (yoghurt,milk,cream, kefir,quarketc.)•Fruitprocessing (jam,plumandapple purée,etc.)•Foodindustry (mustard,spreads, delicatessen,etc.)•Non-food (pastes,gels,creams)

DOSOMAT16AS–RotaryMachineWithSterilisationofPackagingMaterial

Thelaminarairflowcabinetwiththeprescribedfilterclassescombinedwiththesterilisationofthepackagingmaterialsgiveacleanroomwhichisparti-cularlysuitableforthefollowingapplications:

•Useofpackagingmaterial wherecontaminationmay bepresent

•Useinroomswithair contaminationwhere mouldsandotherbacteria spreadthroughtheair•Useinroomswithlow ceilingandwithahigh aircirculationrate•Useinroomwheretraf- ficpassesthrough(loading trucks,transportofgoods)

Bucket sealing from rollstock Cup sterilisation with H2O2

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Our References Our References

Cream CheeseYoghurt /Desserts

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Our References Our References

DelicatessenSaladsButter /Margarine

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Our References Our References

PetFoodMeatPies

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FillingofCosmeticProductsOur References – Coffee / Jam / Fruits / TechnicalArticles

DOSOMAT rotary machine withbufferrotarytableandin-feedconveyorforfillingcosmeticproductsintoplasticorglasscups.