Theegarten-Pactec’s BHS high-speed machine for bouillon cubes is said to set a ‘new speed record’ with an output of 3,000 packaged products per minute, offering additional features for minimized downtime, increased hygiene, and more.
Three versions of the BHS are currently available. One is designed for pre-formed cubes and is said to reach a total output of up to 3,000 packaged products per minute; the model for double cubes aims for 2,500 packaged units or 5,000 individually packaged products per minute; and the pre-formed tablet model achieves a similar rate of 2,500 packaged products per minute while also offering compatibility with Theegarten Pactec’s BLM high-performance cartoning system.
Apparently, the BSH handles and packs soft bouillon with 30% of the company’s previous minimum pressure resistance; its gentle touch is attributed to the absence of start-stop movements during the packaging process, with the continuous flow of movement reducing the acceleration forces acting on the products while increasing output.
The machine can be connected to existing presses for manufacturing bouillon cubes and tablets. A single operator is able to manage a line consisting of a press and a packaging machine – potentially also a BLM cartoning system, in the case of the cube tablet machine variant – or even two lines in close proximity.
Since it requires no lubrication and oil changes are limited to once a year ‘at most’, the BHS is believed to be cost-efficient throughout its life. Energy consumption is set to decrease by 50% per packaged product compared to other packaging machines.
Machine parameters can also be tracked in real time, Theegarden-Pactec explains; this is expected to simplify predictive maintenance and lower the risk of downtime caused by faults. Additionally, the BHS is designed to allow entire assemblies to be quickly, easily, and flexibly replaced, with production able to continue while maintenance is performed on the replacement unit.
Its quality control feature means that faulty products – including pre-formed cubes or tablets that are incorrectly positioned on the conveyor belt, do not comply with the specified height parameters, or are too soft due to incorrectly configured pressure inside the press – can be separated during the packaging process. This is set to ensure that insufficient products cannot impact the efficiency or quality of the packaging process.
From here, the camera-based quality control system identifies and separates insufficiently packaged products; this includes packs wherein the printed image is incorrect, the folding is distorted, or its flaps are incorrectly sealed.
Since all data related to the packaging process is recorded, the BHS is designed to recognize recurring faults, enabling operators to identify and solve the problem. Theegarten-Pactec asserts that the machine achieves a 99.7% rate of ‘qualitatively flawless’ products.
Furthermore, it is designed to enhance hygiene and prevent product contamination in the packaging area – for instance, it only grips bouillon cubes once while they are unpackaged to prevent product abrasion.
They are gripped in the lower section of the packaging process, which continues upwards while abraded particles from the conveyor belts and product grippers fall downwards – preventing contact with the packaging itself. Each product is wrapped 80 milliseconds after gripping to reduce the possibility of abrasion.
The ‘hygienic design’ of the BHS features a paint-free product area, ‘consistently implemented’ balcony construction, and large panel elements, which enable access to the process via a simple pivoting motion.
Going forward, Theegarten-Pactec plans to extend the system’s range to package powdered milk tabs and cubes, confectionary products, and more.
CEO Markus Rustler comments: “Innovation naturally entails significant development costs. We are more than happy to make this investment on account of the strong customer demand.
“We are the ideal partner for manufacturers that are pursuing clear objectives. Together, we are breaking new ground to continuously improve the packaging process.”
In other news, WeighPack Systems’ Swifty Bagger S-3600 Duplex Servo machine is intended to open, fill and seal up to 70 pre-made pouches per minute, or 4,200 pouches per hour. It is applicable to liquid, solid, and powdered products, including snacks, confectionery, meats seafood, and coffee.
ULMA Packaging also seeks to minimize downtime, improve efficiency, and lower film waste by up to 80% with its Width-Flex technology for thermoforming machines. Its motorized bottom web width adjustment system is designed to optimize packaging unit costs, while its operator interface with standard operating procedure allows users to complete format changes in under 45 minutes.
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