The new R3 thermoforming packaging machine from Multivac processes recyclable mono-material packaging films without creasing, requires little maintenance in everyday use thanks to its special design features and adapts to any production environment thanks to its modular construction.
Cheese, sausage, foods made from vegetable proteins, individual items, value packs, mini portions: The abundance of packaging forms and packaging materials for food is becoming more diverse every year. So that manufacturers keep pace with this development has Multivac developed the R3.
The new thermoforming packaging machine is not only capable of, Innovative packaging materials such as recyclable films made from monomaterials for an environmentally friendly circular economy. Thanks to its modular design, the machine can also be customised to meet a wide range of customer requirements. A customised suit for all cases, so to speak. The R3 will be available from July 2022.
„Our aim is to offer best-fit machine configurations to small, medium-sized and large companies with tight budgets. Economical solutions that adapt perfectly to the customer's production environment and are neither oversized nor undersized. Solutions that also minimise maintenance costs.“
Michael Landerer, Product Manager at Multivac
The R3 consists of four stations: the moulding station, the insertion area, the sealing tool and the cutting area. In the first step, the forming station makes the bottom film malleable by applying heat so that a mould can be created for the product during the subsequent thermoforming process using compressed air and vacuum.
After thermoforming, the pack cavities are filled manually or automatically. After loading, the bottom film is hermetically sealed with a top film. Finally, transverse and longitudinal cuts separate the individual packs from the pack web. „In the highest expansion stage, the R3 a speed of twelve cycles per minute and thus achieves the output of high-end slicer lines,“ says Landerer.
In order to protect the environment and slow down climate change, we need to move away from a linear economy towards a circular economy. But a lot of plastic packaging is not ready for this transformation. Why? Because they are made of composite films that cannot be recycled, only incinerated. One solution: recyclable films made from monomaterials - such as APET or PP. They are gaining ground and improving CO2-balance of plastic packaging, but often worsen the visual appearance.
This is because with many thermoforming packaging machines, slight waves form at the edges of the packaging. „To solve this problem, we have developed the R3 equipped with a full-surface heater that heats recycling film evenly“, explains Landerer. In addition, the chain guides for film transport are individually adjustable and decoupled from all process forces of the machine. For example, the weight of the mould set rests entirely on the side frame. This means that no vibrations are transferred to the film. „This enables us to achieve constant film tension and Reliably avoid waves at the packing edges. This guarantees an optimised appearance of the packaging for films made from monomaterials such as polypropylene.“
The R3 is also designed to minimise maintenance requirements. This is demonstrated by the design of the new lifting unit. „The developers have minimised the number of moving parts. In addition lubricant is not used at any point“, says Landerer. „The susceptibility to errors and maintenance costs are correspondingly low.“
The sealing plate can also be changed very quickly. Previously, technicians often had to lift off the entire upper part of the mould. 100 kilograms, which causes a lot of sweat. The solution: The sealing plate, which alone weighs only around 20 kilograms, can be removed from the upper section using screws and pulled into the insertion area. There, a change is done quickly and effortlessly. „The cooling circuit in the upper section remains untouched. That's a huge advantage. Because it is no longer necessary to squeeze out cooling water. A step that not only took time in the past, but also posed a risk of contamination.“
Last but not least, the designers have reinforced the frame of the thermoforming packaging machine on the underside. Thus makes it possible to lift the entire machine at a central point - for example with a forklift truck. „Thanks to the reinforcements, it is quicker to vary the position of the machine when changing lines.“
Source: Multivac
