Waldner DOSOMAT 1.1 filling line

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WALDNER DOSOMAT 1.1
rotary-type machine
Cup filling and closing machine
Machine type: DOSOMAT 1.1 - Rotary machine
Drive: Servomotors make Schneider Electric / ELAU PacDrive 3
Loading: 1-lane
Product: Soups without pieces
dips and tzatziki
Filling temperature: Hot and cold filling
approx. 7 - 85°C
Cup: Plastic cup with ears
A 130 mm
total outside 142.9 mm
400 mi filling volume
stackable / unstackable design
Sealing plate: Plastic plate
PP
natural transparent
prefabricated and embossed
with sealing wax
stackable/unstackable
Snap-on lid: Plastic snap-on lid
prefabricated
soft design
automatically stackable/unstackable
Closure: Heat seal and snap-on lid
Machine description
Design: For wet room operation
all product-carrying parts made of stainless steel (DIN 1.4404 = AISI 316L). Structural parts made of stainless steel (DIN 1.4301)
Machine base frame: Frame in modular design. The drive units are easily accessible in the frame. Drives by servo motor with freely programmable electronic cam to ensure smooth starting and braking. Infinitely variable electronic speed control during operation
Frame fitted with cover plate
Servo technology: Servomotors from Schneider electric (ELAU) with high-resolution multiturn encoders are used. Motion control and machine control by means of ELAU PacDrive TM (programmed according to IEC 61131)
Bucket cells: The bucket cells are designed with a quick-lock system. This enables a very simple and quick changeover to a different format size without the use of tools
Cup stacker: For destacking the cups from the vertical magazine. The destacking technology guarantees maximum machine availability
Cup check: If a cup is missing
the Kontrol device switches off the DOSOMAT. Error is shown on the display
Dosing: Piston dosing for soups and dips: Dosing works according to the piston dosing system. The product is sucked out of the product container by the dosing piston and ejected into the bowls via a changeover valve
The cups are lifted during dosing for optimum filling quality
Filling volume: 100 - 500 ml
adjustable via electronics
Filling volumes of 750 ml are filled with 2 filling cycles
Product container: Funnel
conical
approx. 40 | volume
with double insulating jacket
with cleaning ball and level control (make Levelflex
identical to machine 12.3 - 2846 supplied) to control the customer's product pump
with agitator to prevent the soup from settling
With drip tray to collect condensate drops. Dosing unit and hopper in CIP/SIP design
ready for connection to the customer's central CIP system
Hopper designed with spray balls and level control. The CIP return pump for the cleaning media is provided by the customer
CIP feed pump: approx. 7,000 |/h with approx. 2 bar
CIP return pump: approx. 8,000 I/h
Lid setter board: The prefabricated lids are sucked out of the magazine by vacuum suction and placed on the cups
Lid denesting by means of special cams to ensure correct separation
Air is blown in to support the separation
Sealing station: Pneumatically driven sealing station
Latest design of sealing tools in terms of sensor and heating cartridge arrangement
as well as choice of sealing material and ease of maintenance. The sealing tools are mounted
(movable)
which allows them to compensate for unevenness in the sealing surface
Each sealing head is equipped with a separate temperature controller (via PLC)
heating cartridge
temperature sensor and is therefore individually adjustable
The machine stops if the sealing temperature falls below the set tolerance value
The sealing station can be folded up for cleaning purposes
for cleaning purposes
Snap-on lid setter: The prefabricated snap-on lids are sucked out of the magazine by vacuum suction and placed on the cup
Lids must be stackable and machine destackable
Inverted lid check: If an inverted lid is missing
the control device switches off the
DOSOMAT switches off. Error is shown on the display
Removal: Lifting and pushing the tubs onto a conveyor belt
approx. 1,000 mm long. The buckets are discharged in 1 row
Output: approx. 20 - 25 cycles / min = 1,200 - 1,500 cups / min
with 400 ml soup
depending on product consistency
volume
residual headspace height
cup size and packaging material
Output adjustable via electronics
Energy
a) Electrical system
Control and Motion Control ELAU PacDrive
230/400 V
approx. 7-8 KW connected load
Complete electrics/control unit installed in stainless steel
installed
The control cabinet is attached to the machine. A touch panel with plain text display and all necessary operating elements is installed in the control cabinet. The control system is programmed so that all stations switch on automatically at automatic start and switch off again automatically when the machine is empty
b) Compressed air
FESTO technology
approx. 300 NL/min - provided by the customer
c) Vacuum
Dr Busch vacuum pump
oil-free
Including modem for remote maintenance of the machine via internet connection
The DOSOMAT complies with the current regulations of the ‘Food and Luxury Food’ trade association. The DOSOMAT complies with the current harmonised EU standards and is supplied with CE marking. The machine is protected on all sides by safety doors
on all sides. When a door is opened
a safety limit switch
machines ‘emergency stop’. The safety control system is manufactured by ABB (Jokab Safety). Safety doors made of special polycarbonate LEXAN Margard. This plastic has an additional surface coating and is therefore particularly resistant to cleaning agents and scratches
Extras
Format set with quick-change system @ 75 mm
Format set for additional cup format @ 75 mm
Cups must be designed to be stackable/unstackable. 1-lane
Closure type
Heat-sealing of a plastic sheet
PP
natural transparent
prefabricated and embossed
with sealing wax
stackable/unstackable
and inverting
Complete format set with all parts required for this cup format
in particular
Cup
blank and slip lid magazine
Quick-change format plates
Sealing tool
Small parts
The cups are filled using the existing dosing system without any modifications
Clean air bonnet
Construction of a laminar air flow cabin on the machine
consisting of
Doors made of Marguard® Lexgard® material (surface-tempered polycarbonate)
Attached sterile air module with its own sterile air generation via large-area filters and ring duct blower
Pre-filter in class G 4 according to EN 779
Main filter in class H 14 in accordance with DIN EN 1822
The bonnet generates clean air in accordance with cleanroom class 100 = cleanroom class ISO 5 in accordance with VDI 2083
A gauze is fitted under the filters
which serves as splash protection and for fine air distribution
The laminar cabin is designed in such a way that cup and lid stacks can be added without
opening the doors and thus without stopping the machine and without interrupting the laminar
interruption of the laminar clean air flow
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