zenobia – vertical form, fill and seal machine...vertical form, fill and seal machine zenobia the...
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ZENOBIA – Vertical Form, Fill and Seal Machine
WE DON'T JUST PRODUCE MACHINES, WE ACTIVELY CONTRIBUTE TO YOUR SUCCESS
„Products and Services made in Germany – 100 %. Here at TEEPACK, each little gear
firmly grips the next – from our innovative ideas combined with sophisticated technol-ogy and high cost saving potential, eco-friendly aspects and excellent manageability in everyday operation, right down to the all-important protective functions to safeguard premium products. Our clients around the world benefit from virtually unrivalled quality coupled with extremely high production speeds. The result is a product spectrum that opens up new opportunities with flexibility, and which provides them with the competi-tive edge that nobody can do without in today's quickly changing markets. Rely on our competence and knowhow for your continued success!„
Roland DelapilleMember of the Board
Reinhold Schlensok CEO
Thomas KalinowskiMember of the Board
Dr. Stefan LambertzMember of the Board
PRODUCT AND SERVICES MADE IN GERMANY – 100 %
One of the most important characteristics of TEEPACK is the fact that all of our products, from the smallest parts to complete systems, are made in Germany. And our service will always be in line with the highest German standards.
We have formulated all of this into our promise to you: Products and Services made in Germany – 100%
THE SOLUTION YOU HAVE BEEN LOOKING FOR
Experience, knowhow and lots of ideas are waiting for you
Flexibility and efficiency are criteria that are no longer mutually exclusive – thanks to ZENOBIA with its pat-ented Air Free System and the innovative folding and tagging machine FM260. This system allows the continuous production of as much as 100 block bags per minute. Maximum capacity with a minimum of space requirement is no longer wishful thinking, instead, innovative technology has made this dream a profit-able reality.
Benefits and Technology | 5 |
INCREASE YOUR EFFICIENCY WHILE REDUCING COSTS
RELY ON OUR INNO-VATIVE TECHNOLOGY FOR PREMIUM QUALITY PRODUCTS
Increased efficiency due to high system capacity and reduced packing material requirements
Low maintenance costs, high life expectancy and maximised avail-ability due to a wear-free design and superior quality
Highly flexible because of simple and easy, user-friendly format changes
The continuous working process allows for the production of up to 100 block bags with folded and tagged top flaps per minute, with only a single format tube
Innovative Air Free System produces air reduced bags with compressed product in one sin-gle work step
Reproducible production pro- Reproducible production pro-Reproducible production pro-cesses are ensured by way of electronically controlled servo motors
VERTICAL FORM, FILL AND SEAL MACHINE ZENOBIA
The ZENOBIA's drive system is geared towards maximum capacity: With a production of up to 200 bags per minute, this machine sets a new benchmark for efficiency and guarantees the most economical use of your production equipment and materials with its superior flexibility. Its
modular system design and comprehensive equipment kit provides excellent adaptability for any requirement. The ZENOBIA can be used in virtually all areas of bag packaging, making it the perfect choice for your business.
THE FLEXIBLE AND EFFICIENT FORM, FILL AND SEAL MACHINE FOR THE PACKAGING INDUSTRY
| 6 | Vertical Form, Fill and Seal Machine
Vacuum operated Draw-off Belts
Vacuum operated draw-off belts ensure an almost friction-free transport of the packing material at the format tube, thus ensuring smooth film processing.
Cross-sealing
Continuous pressure du-ring cross-sealing suppor- ted by water-cooled servo drive. Monitoring of the drive allows the detection of product in the cross-seam. The design of the drive system is based on an extra-long cross jaw stroke, which allows for the trouble-free process-ing of all types of films with extended sealing intervals.
Contact-free Longitudinal Sealing
Precise temperature control is ensured by way of the innovative, contact-free longitudinal sealing system with pressurised hot air. This system is extremely low-wear. The longitudinal sealing jaw is positioned by a servo drive.
Format Quick-Change System
The format tubes of the ZENOBIA can be quickly and easily exchanged with just a few simple manual steps. Machine set up times are reduced to a minimum.
THE BENEFITS ZENOBIA
User-friendly – easily accessible machine room, easy data input, automated processes
Low maintenance – sturdy construction, high quality, corrosion-free components
Continuously high performance – water-cooled servo motors, air-conditioned electric cabinet
Process safety – maximised automation, precise quick-change systems
Low maintenance costs – wear-free structure, contact-free longitudinal seal
Gentle film processing – non-slip guide
Flexibility – quick format changes
High bag quality – tight, precisely sealed seams, robust, reproducible manufacture
Gentle packaging process – dampened product impact
Maximised bag variety – modular equipment system
Minimised machine down time – online diagnos-tics performed by service department
Vertical Form, Fill and Seal Machine | 7 |
1 Pillow bag 2 Side folded bag 3 Gusset bag 4 Corner seal bag 5 Clipfix bag 6 Chain bag1
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Active Film Unwinding
Continuous and slip-free film guidance is ensured by the active film unwind-ing with controlled drive and dancer system.
TEEPACK Software
Automatic calculation of the optimised parameters for each format after initial base data input. Quick format change and minimal set up time due to automatic data reten-tion. Clear and concise user interface, customer-friendly programming, touchscreen and indus-trial PC.
Film Tracking Control
The film carrier unit and the film tracking control allow for non-stop and exact film guidance. The position of the film can therefore be corrected automatically while pro-cessing.
Machine-integrated Electric Cabinet
Process-secure and re - producible machine opera- tions are supported by electronically controlled servo drives. The ma-chine-integrated electric cabinet is air-conditioned, and the servo drives of the main drives are ad-ditionally water-cooled to ensure continued high performance.
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The bag is held in position by two guide plates 1 and the panning lifter 2 before it is sealed.
The lifter furthermore 2 aligns the bottom seam on the bottom of the bag. After cooling, the bottom seam remains in its exact position.
The lifter 2 lifts the bag underneath the folding plates 3 to allow the side folders to drive the film in precisely over the product. If the packaging material needs to be compressed, the guide plates 1 can be set to vibrate.
Simultaneously, the lateral jaws 4 close the top seam and build an air-reduced bag.
AIR FREE SYSTEM The patented Air Free System of the ZENOBIA is integrated below the cross jaws and is a true multi-tasker. In just one single process step, the bag is sealed, the product
is condensed, if required, and air is dispersed from the bag – all that without any need for additional machinery or wasted packaging material.
TECHNOLOGY AT THE HIGHEST LEVEL
| 8 | Air Free System
The Functional Principle of the Air Free System
S Y S T E M
Density Control System
Here, changes in the density of the product are captured – which triggers an adjustment of the bag production. The fill height of the product is registered and stored by a pressure-sensitive device on the lifter. Should deviations occur repeat-edly, then a step motor will correct the position of the folding plates.
Aligned Bottom Seam
The stability of the bag is ensured by the pan-ning lifter of the Air Free System. It turns over a defined bottom seam while the material is still warm.
Gentle Product Densification
The optimised activation of vibration impulses allows the product to be gently condensed in the Air Free System during production.
THE BENEFITS AIR FREE SYSTEM
Increased efficiency – high nominal capacity of up to 100 bags per minute
Environmentally friendly and economical manu-Environmentally friendly and economical manu-facture – no packaging material waste
Up to 10 % of packaging material saved – mini-mised top flap by sealing the head seam directly above the product fill height
Minimal footprint – multi-tasking concept of the Air Free System
Increased bag stability – aligned bottom seam
Constant quality of air-reduced bags – process integrated fill height adjustment
Easy gassing option – bag closure on the machine
Air Free System | 9 |
Air Free Bag
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| 10 | FM260
Extreme economy is the distinguishing mark of the ZENOBIA with inte-grated Air Free System and the folding and tagging machine FM260. Continuous work process-es and automated folding steps interlink seamlessly.
The Air Free System pro-duces air-reduced bags with condensed content – the bag fin no longer needs to be cut off.
Function of the Folding and Tagging Machine FM260
The folding unit, which is carried along on the convey-or belt during the folding process, effects a relative standstill for each bag to ensure that process steps 1 – 3 can be carried out exactly and safely.
1 Exact alignment of the top flap
2 Optional single or double folding of the top flap
3 Fixing of the folded top flap with a re usable tag
FOLDING AND TAGGING MACHINE FM260MAXIMISED CAPACITY WITH MINIMAL SPACE REQUIREMENTS
FM260 | 11 |
THE BENEFITS FM260
Increased efficiency – up to 100 block bags per minute with one single form tube
Reduced operating costs – minimum space requirements
Up to 10 % packaging material saving – process- integrated Air Free System
Low maintenance costs – good visibility, accessibility and wear-free drive system
High versatility – automated format change
High machine availability – minimised format change times
Excellent process security and reproducibility – automated, continuous manufacturing process
High bag quality – the dimensional stability of the film is overcome gently in just a few process steps
Block Bag
Bag Transfer
The air-reduced bag is transferred via the Air Free System to the conveyor of the FM260.
Automated Format Change
Format changes occur without the need to ex-change mechanical parts. All movements are carried out via servo motors and spindles. All settings can be stored as recipes and called up as needed for format changes.
Automated Height Adjustment
Deviations in bag heights can be compensated with an automated height adjustment of the folding units. Measurement data of the density control system is transmitted to the FM260 by way of an electronic coupling.
| 12 | Options
We provide the best possible service because we know that you want to achieve more. The ZENOBIA has a Service-Plus system that will keep pace with your demands. Various products can be combined with all stand-ard dosing techniques. The patented Air Free System, an automated gassing system, and the valve application ensure superior product quality.
And with the edge sealing device and the tab appli-cation, your products will not only be packed ex-pertly, but also presented very attractively.
OPTIONSTHE ZENOBIA CAN DO EVEN MORE: UTILISE OUR COMPREHENSIVE SERVICE SPECTRUM TO FURTHER YOUR SUCCESS
Dosing Systems
The ZENOBIA can be combined with all stand-ard dosing devices. For you, that means superior flexibility and optimised capacity for the process-ing of a wide variety of products. From our own manufacture we can, for example, deliver volumet-ric cup or auger dosing systems.
Auger Filling System
Our auger dosing system will never be fazed by exact dosing require-ments for powdered or granulate-based products. The steplessly adjustable auger speed allows for extremely high precision.
Cup Dosing System
Where free-flowing, pieced or granular prod-ucts are to be packed volumetrically, the cup dosing system offers the best solution. It is characterised by its quick and easy cup exchange system, which allows the system to be adjusted to required volumes in no time.
Gassing System
Oxygen-sensitive prod-ucts are effectively pro-tected by the automated integration of nitrogen or noble gases in the packaging process. Your benefit: Superior product quality and longer shelf life, since harmful envi-ronments will not affect your product.
Options | 13 |
Valve Application System
A valve ensures the form stability of the packag-ing, because they are no longer pressurised by outflowing gases and your product is optimally protected. This ZENOBIA application allows the attachment of up to 100 aroma or overpressure valves per minute on the flat, unformed foil length by way of ultrasound technology.
Automatic Roll Changer
Cut out down times and maximise efficiency with automatic roll changes during production. Splic-ing can be timed to occur between roll changes.
Corner Sealing System
Our patented, contact-free sealing system allows the continuous manufacture of up to 100 corner seal bags per minute. Premium quality product presentation and improved product stabil-ity is therefore guaran-teed. The longitudinal sealing seam can be po-sitioned inside a sealing edge, which leaves more space for printing.
Label Application
Enhance the appearance of up to 80 bags per minute with high-quality, cardboard labels with a size of up to 80 – 180 mm, e. g. on premium tea bags made of nylon, the label is applied by way of ultra-modern ultrasound technology.
Pasta
Fusilli, farfalle, rotelle … pasta can be made in an endless variety of types and shapes. Frequent product changes entail form changes and the reconfiguration to other bag types in the packa-ging process.
The ZENOBIA can deal with these requirements easily because of its well thought-out quick change system for speedy form changes, which means that machine down times can be kept to a minimum.
Furthermore, the ZENOBIA can produce all standard size bags for pasta. Tube
bags, block packaging or bags with a clip – you provide the variety, and we provide the solution that brings it all together.
Rice
Benefit from the knowhow that TEEPACK has accu-mulated in long-standing partnerships with many big-name rice manufac-turers, and utilise it for your own production environment. The folded and tagged block bag has always been the favourite among rice packaging options, and ZENOBIA can handle this type of bag particularly well in high-speed and premium quali ty production runs.
The head sealing can alternatively be produced in such a manner that a user-friendly pouring option is provided.
TEEPACK will addition-ally provide you with a comprehensive, all-round solution, including our own cup dosing system. Here is your opportunity to push your product into the foreground of con-sumer awareness – with premium quality packa-ging.
INDUSTRIES, APPLICATIONS, SOLUTIONS
| 14 | Industries, Applications, Solutions
WE CALL IT MULTI-TALENT. THE ZENOBIA CAN HANDLE THEM ALL: PASTA, RICE, SWEETS OR COFFEE – THE SYSTEM OFFERS THE RIGHT TYPE OF BAG FOR ANY CONTENT. TAILOR-MADE SUIT TO YOUR REQUIREMENTS.
Sweets The market for sweets and snacks is one of the most competitive in the food sector. Take a step ahead of the competition by adding an edge seal or product specific form to the packaging. The ZENOBIA offers virtually boundless flexibility.
The ZENOBIA is easily integrated into produc-tion line processes for poured goods. Products will no longer need intermediate storage and can be packaged immedi-ately downstream of the pouring unit in one single processing step – saving you time and money.
For easily breakable sweets, e. g. cookies, the moving cross jaws diminish the force of the impact – thus effectively reducing breakage.
Whatever the specific requirements of your product – we will assist you in optimising your production process.
Coffee The secret of a great coffee lies in its specific aroma – and with it of course its proper packaging. And to ensure that none of that precious aroma can escape on the way to the consumer, our ZENOBIA provides the perfect protective gas envi-ronment for your product. An aroma protection valve in the bag elimi-nates the danger of oxida-tion of the product, while gases produced inside the bag can escape, while it keeps its desired shape.
The valve is attached by next generation ultra-sound technology.
Of course the ZENOBIA can handle coffee beans just as well as ground coffee or coffee powder. In block packs or with sophisticated edge seals – your product will always be presented to its best advantage.
Industries, Applications, Solutions | 15 |
1 Pillow Bag 2 Side Folded Bag 3 Gusset Bag 4 Corer Seal Bag 5 Clipfix Bag 6 Chain Bag 7 Air Free Bag 8 Block Bag
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INDUSTRIES, APPLICATIONS, SOLUTIONSEXCELLENT PACKAGING. FOR ANY PRODUCT – FROM TEA TO CEREALS AND FROZEN GOODS, RIGHT DOWN TO NON-FOOD PRODUCTS. THE ZENOBIA'S RANGE OF APPLICATION IS VIRTUALLY ENDLESS.
Tea Being the inventor of the double chamber tea bag, we can look back on de-cades of experience and know everything there is to know about tea, and use that knowledge for packaging it in vertical tube bags.
The low weight of the tea means slow fall times and after-spills into the sea-ling seam – that is why we developed an option to prevent just that.
In addition to the optional packaging of tea in block bottom bags or gabled bags, a label application was developed to pro-
duce premium quality tea bags with the ZENOBIA. That means that you now have an opportunity to expand your product portfolio and utilise busi-ness opportunities at the point of sale.
Cereals
The bag-in-box packaging for cereals is the favou-rite type of cereal pack-aging to date. For corn flakes or the traditional muesli with fruits – TEEPACK can offer you the complete production process for your bags from start to finish.
With the help of our Air Free System, the pro duct will always be optimally condensed. The sur-rounding carton can therefore be designed to be smaller than traditional cartons – you save on material and costly shelf space.
The product is, of course, condensed with utmost care to prevent any un-wanted breakage.
And if you prefer other packaging types, e.g. clip bags or edge-sealed bags for your products, the ZENOBIA equipment kit will have the right tools for you as well.
| 16 | Industries, Applications, Solutions
Frozen Goods
Frozen goods have very specific requirements in terms of packaging, as the products are often ir-regular in their shape and consistency. We believe that the machine must be able to adapt to the pro-duct – not vice versa.
That is why the ZENOBIA will fit perfectly into your production flow and will help ensure the continu-ity of your cold chain.
Our optimised sealing process with robust seal-ing seams will protect your product against con-tamination, infection with micro-organisms, drying
out, liquid penetration and external aspects that could influence the smell or taste of your product. And the machine is very easy to clean.
Hygiene and quality are our focal points and gua-rantee that your frozen goods will remain at the peak of their quality.
Non-food Our solution portfolio is just as varied as the product variety in the non-food sector.
You want to pack dowels in a bag with a cardboard tab? That is what our tab application system is for. You are dealing with washing powder in block bottom bags? We can provide the entire process from dosing to high-speed packaging.
Contact us and we will work with you to find the perfect solution to suit your requirements. Don't settle for standard sug-gestions; we specialise
in developing individual concepts that are a per-fect match for you and your product – our credo is:
"get 100 %"!
Industries, Applications, Solutions | 17 |
1 Pillow Bag 2 Side Folded Bag 3 Gusset Bag 4 Corer Seal Bag 5 Clipfix Bag 6 Chain Bag 7 Air Free Bag 8 Block Bag
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PACCOM
TA
NOBIA
FECPER
TA
TEA BAG PACKAGING MACHINE
PERFECTA Tag PERFECTA Envelope PERFECTA Universal PERFECTA HS Peripheral Equipment Options
COMPACTA Tag COMPACTA HS Peripheral Equipment Options
TEEPACK PORTFOLIO
| 18 | Portfolio
VERTICAL FORM, FILL AND SEAL MACHINE
ZENOBIA Basic Machine ZENOBIA Air Free System ZENOBIA Folding and Tagging
Machine FM260 Peripheral Equipment Options
BENEFIT
High life expectancy and low maintenance costs
Maximised machine availability
Flexibility in terms of applications and pro- Flexibility in terms of applications and pro-Flexibility in terms of applications and pro-duction
Less packaging used
BENEFIT
Lower production costs
German premium quality and perfection
Reliability
Flexibility
Superior safety standards
High production efficiency
Time saving during changeover of packaging materials
TECHNOLOGY
Shorter maintenance times
Less staff requirements
Replaceable parts
Optimised precision
Quick format changes
Low spare parts consumption
Optionally with knot or staple, with later retrofit option
TECHNOLOGY
One central drive motor
Optionally with knot or staple, with later retrofit option
Low power consumption
Basic version does not require compressed air
TECHNOLOGY
Continuous mode of operation allows for maximised capacity of up to 200 bags per minute
Reproducible manufacturing processes, since all functions are carried out by elec-tronically controlled servo motors
Modular machine design with extensive equipment options for multiple applications
Quick form change due to maximised auto- Quick form change due to maximised auto-Quick form change due to maximised auto-mation and precise quick change systems
BENEFIT
Low acquisition price
Quick changeover from heat seal envelopes to naked bags and vice versa
Easy handling
Option for use of simple heat seal foils
Benefits and Technology Overview | 19 |
| 20 | Service Quality
TECHNOLOGY AND SERVICE BASED ON A SOLID FOUNDATION: OUR UNRIVALLED QUALITY
Service Quality
PHASE A Planning Consult with our highly qualified application engineers
before committing to your investment. Only then will you be absolutely certain of knowing, which the most efficient for you is.
PHASE B Commissioning Our experts will support you on-site and on every step of the
way: from startup support to production tests right down to system optimisation.
PHASE C Operation Maximum availability of your production line means compre-
hensive service support by us – for example, in the form of system support and optimisation, professional maintenance management, a 24 hour hotline and of course operator train ing.
PHASE D Retrofitting/ Optimisation We will adapt and optimise your existing machinery to ever
new requirements, so that your equipment will keep its value now and in the future. Our offering is rounded off with com-prehensive services, which include OEM parts, customer- specific maintenance intervals, service contracts, a 24 hour hotline, and also standard or customised staff training courses.
SQ Expert advice on-site Electrics approval and
handover
Mechanics approval and
handover
Adjusting the lower blade
Excellence is the most important aspect for TEEPACK. It begins with project planning, includes the training of your machine operators, and continues on to after sales service and an electronic spare parts catalogue – quick response remote maintenance included.
Our commitment to quality will remain useful to you for many years after the initial purchase of your machine, because we will continue to offer quick and effective support on the phone, minimising system down times and technician travel costs. Your trust is well-placed, because our technology and service have a globally leading name: TEEPACK.
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Technical Quality | 21 |
Technical Quality
1 Highest level of efficiency
You benefit from superior efficiency with lowest per-bag prices.
2 Proven longevity
We combine above standard material quality with low-wear construction. Because of the module-based system expandability and long-term spare parts and customer service availability, your investment will be secure far into the future.
3 Highest reliability
All our parts are manufactured by qualified professionals at our own highly sophisticated machine park in Germany.
TQ
"OUR SERVICE SPECTRUM AND SCOPE IS JUST AS IMPRESSIVE AS OUR PIONEERING ENGINEERING."
PHASE D
PHASE A
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PHASE C
P
HASE B
| 22 | ZENOBIA
THE SOLUTION YOU HAVE BEEN LOOKING FOR
ZENOBIA | 23 |
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MATERIAL AND TECHNI-CAL DATA OVERVIEW
1 Pillow Bag2 Side Folded Bag 3 Gusset Bag4 Corer Seal Bag 5 Clipfix Bag 6 Chain Bag 7 Air Free Bag
1 Pillow Bag2 Side Folded Bag 3 Gusset Bag4 Corer Seal Bag 5 Clipfix Bag 6 Chain Bag 7 Air Free Bag 8 Block Bag
1 Pillow Bag2 Side Folded Bag 3 Gusset Bag4 Corer Seal Bag 5 Clipfix Bag 6 Chain Bag
| 24 | Material Data
ZENOBIA BASIC MACHINE
ZENOBIA AIR FREE SYSTEM
ZENOBIA FOLDING AND TAGGING MACHINE FM260
Bag Specifications
Bag width (mm) min. 60 max. 280
Bag depth (mm) min. 40 max. 100
Pull-off length (mm) adjustable
Film Specifications
Film width (mm) max. 650
Film roll diameter (mm) max. 550
Film core diameter (mm) 76
Bag Specifications
Bag width (mm) min. 60 max. 200
Bag depth (mm) min. 40 max. 100
Fill height (mm) min. 56 max. 250
Pull-off length (mm) min. 146 max. 400
Top Flap Length (mm) min. 34 max. 100
Film Specifications
Film width (mm) max. 650
Film roll diameter (mm) max. 550
Film core diameter (mm) 76
Bag Specifications
Bag width (mm) min. 60 max. 200
Bag depth (mm) min. 40 max. 100
Fill height (mm) min. 56 max. 250
Pull-off length (mm) min. 146 max. 400
Top Flap length (mm) min. 34 max. 100
Film Specifications
Film width (mm) max. 650
Film roll diameter (mm) max. 550
Film core diameter (mm) 76
MATERIAL DATA
Technical Data | 25 |
Weight (kg): 1,950
Nominal capacity (bag/min.): 100
Weight (kg): 1,680
Nominal capacity (bag/min.): 100
Weight (kg): 1,600
Nominal capacity (bag/min.): 200
TECHNICAL DATA
Power connection: 230/400V, 50 Hz, 3Ph, N/PE; Compressed air min. 6 bar; Air consumption: 600 – 1.200 Nl/min; Protection type: IP54; Device colour: Stainless steel V2A; Technical changes reserved Notice: Machine dimensions in mm
Power connection: 230/400V, 50 Hz, 3Ph, N/PE; Compressed air min. 6 bar; Air consumption: 600 – 1.200 Nl/min; Protection type: IP54; Device colour: Stainless steel V2A; Technical changes reserved Notice: Machine dimensions in mm
Power connection: 230/400V, 50 Hz, 3Ph, N/PE; Compressed air min. 6 bar; Air consumption: 600 – 1.200 Nl/min; Protection type: IP54; Device colour: Stainless steel V2A; Technical changes reserved Notice: Machine dimensions in mm
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TEEPACK Spezialmaschinen GmbH & Co. KGDusseldorfer Strasse 73D-40667 Meerbusch
Tel.: + 49 (0) 21 32 / 9 76 - 0Fax: + 49 (0) 21 32 / 9 76 - 1 00Email: [email protected]
www.teepack.com