Meypack expands its machine program with a completely new palletising machine – and offers in addition to the existing PK 110 and PKO palletisers a highly efficient and flexible solution for the food and beverage industries. The machine reaches a speed of 30 bundles per minute, and that in a space of only 10 m2.
The idea to develop a new palletiser grew out of the desire to save space by shortening the distance between the packaging machine and the palletiser and to simplify the handling for the customer by directly connecting the packaging machine to the palletiser and controlling both machines with one control system. Save space, simplify the control system and in doing so, reduce costs – that is precisely the concept behind the new PackPal.
Originally designed to be combined with VP Series case packers of every capacity for the transport of trays, trays with lids and wrap-around cases, in the meantime it is now possible to combine the PackPal with machines from the SW and FW Series. To carry this out, a small modification of the product transport is necessary between the two machines. However, the PackPal can also be used as a palletiser on its own.
High-tech solution in CleanDesign
As with all machines from Meypack, the new PackPal is built according to the CleanDesign Construction Principle. The machine is designed in an open manner, providing good accessibility to the products, the pre-grouped layer and all modules and areas of the PackPal, which in turn facilitates cleaning and maintenance. Especially in palletising technology, the open design is a real novelty and aids in shortening periods of standstill, significantly reducing the maintenance and cleaning costs and simplifying operation for both the operators and the service personnel. The machine is available in steel or in stainless steel versions.
The assembly of the PackPal on site at the customer is easier and faster to complete, which not only prevents machine downtime but also drastically reduces commissioning costs. The entire machine can be installed and commissioned within 1 or 2 days thanks to the extremely compact design of the PackPal. All components can already be mounted at the time of delivery.
However, it is not only the low commissioning costs and the ease of use that make the PackPal an economically attractive overall solution but also the minimal space requirements enable an optimal utilisation of space. For example, the PackPal version with just one gripping arm (PP 100) for low speeds requires just around 10 m2 while the version with two gripping arms (PP 200) for high speeds requires no more than 20 m2. The PackPal is no slouch when it comes to speed either: it can process 30 (PP 100) respectively 60 (PP 200) packs per minute. Both the PP 100 and the PP 200 can process all current pallet formats. Furthermore, the integration of intermediate layers or cover sheets is easily possible.
The new Meypack telescopic lifting table enables the continuous flow of products through the packaging machine during an automatic pallet change
In the scope of the development of the PP, Meypack completely reconceptualised the lifting table. The result is a lifting table equipped with a telescopic device that is capable of not only moving up and down, forward and back, but that is also able to contract to half its original length. The new telescopic lifting table extends outwards above the pallet and lowers itself onto the layer. With the help of layer holders located in front of and behind the layer as well as the proven side centring device, the layer cannot slip. Through this technique, a creation of gaps between the products is easily possible in all imaginable variations. The underside of the lifting table frame is additionally equipped with scanners. These monitor the pack surfaces and search for “unevenness” while the lifting table extends above the pallets – an additional safety precaution for a smooth run.
Precise: A gripping arm places the cases on an intermediate table
according to a set palletising pattern
The telescopic device on the lifting table also ensures continuous flow of products through the packaging machine during an automatic pallet change. While the full pallet is being automatically transported to the pallet wrapper and an empty pallet is being moved up from the empty pallet magazine, the lifting table simultaneously moves backward to pick up the next layer which it then sets down upon the new empty pallet during the next cycle.
Without interruption: The new telescopic lifting table extends outwards above the pallet
Intertwined: The Meypack PackPal unites packaging and palletising processes into an efficient all-in-one process
When the PackPal is combined with a case packer from the VP 400 Series, the packed cases exit the case packer and are then raised to the height of the palletiser. This process is necessary because the lowering principle used in the VP 400 Series results in product discharge that is otherwise too low for the palletiser. In the case of the continuous motion packaging machines of the VP 500 Series, it is not necessary to raise the cases because the processing level is maintained.
Alternatively one gripping arm of the PP 100 or two gripping arms on the PP 200 remove the cases from the discharge area of the packaging machine and place them on an intermediate table according to a defined palletising pattern. This holds two rows for the PP 100 and one layer for the PP 200, guaranteeing a continuous layer building process, even during a pallet change. The layer pattern takes place only on the front section of the table, which is designed as a belt conveyor and as such provides very short distances for the gripping arm. The next layer is transferred as soon as the lifting table has retracted again and once again abuts on the intermediate table.
The gripping arms consist of a four-pivot positioning device and can be rotated 360 degrees. They move sideways as well as forward and back. If two gripping arms are used, the intermediate table is loaded from the left and the right sides. It is possible that depending upon the selected palletising pattern, the individual packages protrude over the middle and interconnect. The control software programs the arms asynchronously so that only one arm is above the table while the other arm picks up the next package from the discharge area of the packaging machine.
This layer-packing procedure is reflected in the first part of the name “PackPal”. As soon as a layer has been fully created, the lifting table extends outwards and sets the layer onto the pallet. This procedure is represented by the abbreviation “Pal”. So, both procedures are referred to in the name PackPal as well as in the abbreviation PP.
Extra task for the gripping arm on the PP 100: Fully automatic exchange of form part in combination with machines from the VP 400 Series
A special, extra feature offered only in combination with the case packers from the VP 400 Series is the fully automatic exchange of form parts, carried out by the gripping arm on the PP 100. In this concept, the head of the gripping arm - standardly equipped for normal case transport with a metal sheet customised to the packages being transported – is replaced by a “finger system.” This enables the gripping arm of the PP 100 to execute a fully automatic exchange of form parts by exchanging parts within the basic frame of the packaging machine. With the help of additional telescopic devices on the gripping arm and a format changeover table that is integrated into the packaging machine, the functionality of the gripping arm can be fully utilised in the combined machine system.
