HCC Filling Line
HART Design & Manufacturing’s HCC Filling Line is designed to reliably fill and package cream cheese with a capacity of 90 gm and 1 kg volumes. Experience for your company why HART is a global leader in the latest servo-controlled, polished stainless steel cream cheese filling equipment.
HART’s HCC Filling Line will Improve the Dependability of your Cream Cheese Packaging with its Servo-Controlled, Polished Stainless Steel Pouchmaker, Conveyor and Filling Station
The pouchmaker section of the filling line forms a pouch from roll stock material by running it through a series of dancer rolls, forming board, and nose piece to ultimately make a gusseted bottom pouch of the proper size.
The roll stock has a maximum diameter of 24 inches with a core diameter of 6 inches. A powered unwind unit pulls the film web from the rolls. A servo web aligner guides the film through a set of stationary and dancer rollers into the forming board. Prior to the pouch forming board, the edge is turned over to provide an “easy opening” feature. The turned over edge also adds rigidity to the pouch which enables the pouch to be more erect in the carton.
The side seal bars section off the film web into individual pouches. Servo driven nip rolls pull the pouches into the opener / inserter section. As a pouch is fed out over the opener / inserter it is held by a pair of vacuum jaws. The pouch is then cut by a shear knife and opened by the vacuum boxes. An expanding mandrel then enters the opened pouch and inserts it into a carton. The pouch assumes a formed rectangular bottom, duplicating the inside dimensions of the formed carton.
The pouchmaker has the capability to run registered or unregistered film. The pouchmaker has a “no carton / no pouch” feature. Defective pouches or cartons are detected and rejected prior to the filling system.
The pouchmaker includes the following assemblies to ensure the reliability and speed for creating packages for your cream cheese.
Each core shaft has side to side adjustment. This is used to keep the front and back top edges of the pouch uniform.
The film is unwound by means of a nip roll. The speed of the unwind is controlled by a programmable variable speed DC drive. An additional nip roll is located near the film cutoff. Constant tension between the nip rolls is maintained throughout the pouchmaker.
Optional items in the unwind area include a splice plate for easy splicing of a new roll material to the end of an existing roll of film (a vacuum holds the web in place while splicing), and a web aligner to maintain the edge position of the film.
The film runs through a former to make a c-fold and to form a bottom gusset to the proper size. It will also turn over the top edge of the pouch. The turned over edge improves pouch rigidity helping the pouch to stay open during filling. Also, it makes the pouch easier to open after sealing. Additional sizes require the changing of the nose piece.
The film goes through the heat seal station. The heating bars are operated by a pneumatic assembly designed for easy vertical and horizontal adjustment.
If a carton is detected, the web is advanced to the opener/inserter section. The pouch is cut to the proper length by a guillotine knife and held in place by the vacuum box. The knife is easy to adjust and inexpensive to sharpen.
The pouch is then opened with vacuum boxes and the pouch mandrel inserts it into the carton for filling. After insertion of the pouch into the carton, the carton is directed to the filler. To make sure the pouch is inserted properly the forming ram expands with use of air cylinders as it is inserted. The forming ram retracts and releases the pouch formed in the carton. The pouched carton then passes through a reject station. In this station, if a pouch is not detected, the carton is ejected.
The Filler, in the second stage of the HCC Filing Line, includes the following components to ensure the speed and reliability of filling cream cheese into the packaging.
The conveyor indexes the cartoned pouch through the various stations of the filling section. A servo motor or camco gearbox drives the filler conveyor. The main AC motor drives the forming ram, filler, flaring fingers, and fin seal.
The pouched carton is indexed to the pouch flaring station. It is designed to open the pouch prior to filling. The flarer unit is a vertically-reciprocating unit with flare fingers or rods which extend downward toward the pouch interior.
After flaring, pouched carton is indexed to the fill station. The nozzle is lowered into the pouch for filling. If the viscosity of the cheese changes, the speed of the lowering action can be changed.
The filler is a mechanically powered single piston that measures and dispenses product by volume. The filler has four basic components:
- First, is the fill piston reciprocator, which is accomplished by a shaft-mounted cam. The linkage contains a screw adjustment to increase or decrease the amount of fill piston travel, thus changing the product volume as required. A push button at the operator panel activates a stepper motor that turns the adjustment screw.
- The second is a rotary spool valve located in the hopper base. It permits product to flow from the hopper into the piston-cylinder on the suction stroke. During the filling, it allows the product to be pumped through the nozzle. A photo-eye mounted prior to the filling station senses a carton. It will engage the “no-fill” lockout feature if the photo eye fails to detect a carton.
- The third component is a double acting air cylinder to activate the rotary valve on the nozzle. Upon opening, the cheese flows into the pouch.
- The final component is a product agitator inside the hopper. The standard hopper is single walled and comes with a one-piece cover. A two-wall hopper is also available. Warm water can be run between the walls to prevent the cheese from cooling or setting. A two-piece hopper cover can be added for simplicity in setting the level of cheese in the hopper especially during start-up.
Once filled, the filled carton indexes to the fin-sealing unit. At the fin sealing station, spreader fingers rotate downward and pull the ends of the pouch outwardly. This motion is caused by a lever and control rod system actuated by a vertical rod connected to a cam operated level arm. After the spreader fingers pull out the pouch ends, two heated seal bars pivot down and fin seal the pouch.
The filled packages will be discharged to a carton sealer. The carton flaps are plowed over, glue is applied and the flaps are closed to seal the carton.