Every product has its own characteristics that need to be taken into account when building a packaging solution. Some products need careful handling, others require specific packaging solutions. In this blog post, we are going to address the topic of bottle and jar secondary packaging solutions. Bottles and jars are used in a variety of industries, but mostly in the food and beverage and pharma industry.
Food and Beverage
Whether it is in a glass bottle or a can – we all like a sip of a good drink. We also enjoy condiments and other bottled goods. Yet, we rarely think about what is necessary for those products to end up on our table. When it comes to packaging or cartoning, bottled products need special handling. Some bottles are wider at the shoulders than at the bottom. Special care is required for these bottles not to tumble over while on the conveyor. Beer, sodas and other beverages are carbonated, so these bottles need to be handled with the minimum of shaking.
Many pharma products like various drops and pills are primarily packed in a bottle. These bottles are usually placed in a small individual carton that also contains a leaflet. Pharma bottles need to be handled with special care in order not to compromise the product. Leaflets need to be inserted into the carton without damaging the leaflet or packaging. Serialization codes also need to be applied on the packaging in order to be compliant with new tracking requirements. These details must be taken into consideration when choosing a secondary packaging solution for bottled pharma products.
Now we will describe bottle packaging process on the example of our TI-50 Vertical cartoner.
Completed Bottle recognition:
The first step in the process of bottle cartoning is bottle recognition. Filled, sealed and labeled bottles will travel on a conveyor where they are sensed by a camera or sensor for presence and accuracy and a signal is sent to the cartoner to erect a carton.
Flat cartons are stored in an extended carton magazine. Upon receiving a signal of the presence of a “good” bottle on the infeed conveyor, a carton is erected into individual carton pockets.
Leaflet inserting (optional) :
A Leaflet is being placed on top of the open carton, and it will, later on, be pushed into the carton by the product itself in a c-fold style.
Bottles coming in on a conveyor will then enter into the bottle loading station where a gripper will positively pick up a bottle and gently place it into the erected carton.
The final step of bottle cartoning is carton closing which can be done by straight or reverse tuck or hot melt glue. Completed Cartons are then verified for compliance with all required operations and then discharged from the machine to one of our tray or case packers. (Any non-compliant cartons are rejected out of the machine for re-work)
So, if you are in a search for compact cartoning solution perfect for bottles or jars, don’t forget to ask us for a quote!
Our vertical cartoners for hand load applications are available with automatic bottle loading and count weigh scale interface. Simplicity, innovative design, robust construction and upgraded craftsmanship result in high speeds and high efficiencies. The 50 series of Vertical cartoners are compact, portable, and easy to use and to changeover. The 50 series of Vertical cartoners feature compactness, portability, simple operation and quick changeover. Carton pockets assure positive carton setup and carton squareness. Whether you need tuck, glue, header, gable, flip-top or hex style carton, TI-50 can handle it all!
Many product manufacturers are asking for multiple quotes when they are about to purchase a new cartoner, case packer or any piece of packaging equipment. This is understandable; after all, getting multiple quotes allows you to review and compare packaging equipment manufacturers and evaluate each proposal.
We are aware that most potential clients almost immediately flip to the price. In many cases, the price alone can make or break the quote, regardless of the information on the other pages. However, basing a purchasing decision solely on price can be a mistake that can cost you more than you think.
Go beyond numbers
So, you got the quotes, now what? When it comes to price, you should dig deeper. What is truly included in that number? In order to determine the best value for your needs, as well as eliminate any unanticipated surprises after the purchase we recommend doing an “apples-to-apples” comparison. This way you can avoid changes in orders, delays, and additional costs.
Equipment manufacturers have different company protocols and different interpretations of what is being requested. As a consequence, prices also vary. There are three common ways packaging machines are quoted:
Package lump sum deal comprised of a base machine with a host of options and services added in
Bare-bones machine with an à la carte list of available ancillary equipment and services
Hybrid package solution that provides some options with the machine and offers additional ancillary equipment and services for separate purchase
Depending on the application and machine, ancillary equipment and services can raise the level of investment by up to 30%, or more. Therefore, make sure to know exactly what is (and isn’t) included in the price. Breakdown the sections of a quote and put it into a vendor comparison matrix. This can help you understand and compare multiple packaging equipment quotes. Sections to include in a matrix include:
Factory Acceptance Test
Spare Parts Kit
Devil is in the Details
Now that you have a vendor comparison matrix, you need to dig deeper to understand what is included in each of the numbers. Lack of detail can stall the purchasing process, and it can cause confusion in the future, especially if it’s not clear what is and was not included in the final number.
These are the critical elements you should look for in a quote when you compare packaging equipment manufacturers:
Breakdown of all system components along with an understanding of how the machine is assembled and the general quality of the build.
Detailed lists of the specific mechanical, electrical and pneumatic components to be used.
What type of electrical controls (PLC/HMI) are being proposed, do they meet both your line needs as well as your existing control structure?
Step-by-step walk-through of the method of operation.
Information regarding the machine’s specific features and benefits.
Machine frame and structure type.
Packaging machine’s utility requirements. If other options are available does it identify them?
Parts warranty and time frame.
Is there a guarantee on system performance?
Supplier’s payment terms.
System delivery schedule.
System testing and acceptance protocols. What can you expect at the FAT? Are both parties in agreement with the testing and acceptance protocols?
Is system testing included in the price?
What services are available after installation (i.e., parts, technicians, preventive maintenance, and special programs)?
With the help of these guidelines, the equipment purchasing manager should be able to easily identify the machine being proposed, the packaging machine manufacturer’s level of expertise, and the true cost of each proposal.
So, if you are in the search for the best packaging machine manufacturer, don’t forget to get a quote from us. We are certain that Tishma Technologies will be your final choice.
Our modern and fast-paced world is all about convenience, which is why the usage of flexible plastic pouches is a continuing prominent trend in product packaging. Global market demand for pouches is projected to rise 6.2% annually to $37.3 billion in 2018. Food is the largest and most developed market for a pouch, followed by pharma/medical and beverage.
Large companies are choosing simple, traditional bag types; pillow style bags and stick-packs. A simplified packaging process, above all, means cost savings and efficiency increment, which contributes to a larger bottom line.
Consumers also love this package format because it is lightweight, convenient, and it complements their on-the-go lifestyles. More consumers are choosing pouches over the traditional glass, paper and metal packaging, and even rigid plastics.
Pouch is a simple packaging format, yet pouch packaging process isn’t as simple as it might seem. Choosing a right pouch packaging solution largely depends on a nature of a product. In order to help you to make the right choice, this blog post will deal with all the steps in pouch packaging process and various optional additions to that process, depending on your packaging needs. All examples are based on Nortech Packaging’s ROO-100 preformed pouch fill & seal packaging solution.
The pouch magazine
Pouch packaging process starts with the pouch magazine. The magazine consists of the servo driven lugged conveyor and auto- adjustable symmetrical guides. Operator places stack of pouches in the magazine cells, where the pouch accurate positioning is assured with the guides and lug relative positions. Based on the pouch starving sensor signal, the servo indexes the belt in order to bring next cell filled with pouches into the loading position.
The servo drives a three head rotary unit to utilize vacuum suction cups to pick a pouch from the magazine and deliver it into the pouch carrier system. Based on the pouch registration sensor signal, servo calculates necessary correction which assures accurate pouch positioning in the grippers.
Pouch carrier system
In order to be transferred through the machine for different operations, a pouch has to be secured between two grippers. This unique design utilizes two servo driven synchronized chain track, where each supports one of the grippers. If filled pouches are too heavy, machine can be built with a conveyor which will provide additional support for the pouch from the bottom.
Pouch opening station
By applying vacuum suction cups in the pouch area above a zipper, the pouch is pre-opened enough to insert mechanical fingers. After inserted, fingers are used to pinch each side of a pouch moving it apart, assuring positive zipper pouch opening.
Pouch filling station
Filling tube moves slightly into the pouch to assure that pouch will form properly to eliminate product spillage. Optionally, additional filling station(s) can be added. Products infeed options are various and they depend on a type of product.
For powder and non- free flowing solids like ground coffee or flour, we recommend auger filler. The main advantage of this system is the ability to control dust during the filling operation. Auger fillers are frequently used in conjunction with a weighing instrument in order to compensate for changes in the bulk density of the product. The fillers of this type are suitable for filling products at both low and medium speeds.
Volumetric cup filler is recommended for free-flowing solids like rice, candies or frozen peas or powders that don’t generate dust. Volumetric cup fillers measure out a product in a cup, with specific predetermined volume. This type of filler is suitable for precise filling of products at both low and high speeds.
For packaging application where measuring precision and accuracy are crucial, we recommend vibratory fillers. They provide you with accuracy, speed, and versatility across a comprehensive line of linear net weigh feeders.
Multi-head weighers can also improve your product packing line. Improved weighing accuracy means more packs per kg of product. Fast calculation time allows you to deliver more packs per shift. Self-tuning vibration system optimizes product flow and simple, tool-free cleaning cuts weighing machine downtime
Robotic infeed is recommended for sensitive and fragile products that demand delicate product handling. Robotic arm with appropriate EOAT can be integrated with ROO-100 for achieving careful and delicate product handling.
The top side of a pouch is sealed with the hot sealing bar. Pouch cooling is an option for pouches that contain products that are sensitive to heat (like chocolate). To get rid of an excessive air in the bag we recommend enhancing your packaging solution with deflators. Sponge or rubber loop deflators push the air out just prior to sealing. For some products like chips and snacks, we recommend using nitrogen gas flushing. Snack bags are designed to protect delicate foods inside from both oxygen exposure and physical damage. The nitrogen replaces the oxygen and cushions the contents. Unlike oxygen, nitrogen doesn’t react with foods, so they stay fresher longer. Nitrogen doesn’t affect the flavor or texture of the food, so it’s perfect for food preservation. So, chips and snack bags are not filled with nitrogen gas just to look bigger.
After sealing options
Metal detector: Metal detector can be integrated before or after pouch fill & seal machine.
Checkweigher can be integrated after pouch fill & seal machine for improved control
Scrap pouches can be removed with the help of a reject station
Labeler can also be integrated after sealing station
Wash-down: ROO-100 can also feature a wash-down construction with NEMA 4x enclosures. This means that the machine can be cleaned with a spray of water without worrying about electric components or rust.
To improve product settlement inside a pre-made pouch after filling we recommend vibratory settlers.
Hole punch / Die cut: Pouches are usually hanged on the shelves in the store; this is why almost all pouches need to have a hang hole. Punching or cutting a hang hole can also be a feature of ROO-100.
There are a lot of pouch fill & seal machines on the market due to the rising popularity of pouch packaging format. However, not all of them are equally good as a solution. Pouch machines are usually large and they demand a lot of floor space. ROO-100 with its compact footprint is the smallest pouch machine on the market. Changeover for some pouch machines can last up to half an hour. With ROO-100 you can change between pouch sizes in 30 seconds! Besides being the most compact machine on the market, ROO-100 is also the most affordable one. As mentioned above, it can be built and integrated with a variety of options and systems according to your specific needs. Get a quote and check why do we refer to ROO-100 as a “world’s new champion in flexible packaging!”