END OF LINE SOLUTIONS A GREAT EXPERIENCE IN PACKAGING

Transcription

1 END OF LINE SOLUTIONS A GREAT EXPERIENCE IN PACKAGING

2

3 Table of contents A GREAT EXPERIENCE IN PACKAGING 2 PHARMA AND NON PHARMA 4 SHRINKWRAPPING MACHINES 6 OVERWRAPPING MACHINES 12 TRAY PACKING MACHINES 18 CASE PACKING MACHINES 20 PALLETIZING STAND ALONE 30 DEPALLETIZING MACHINES 33 PRODUCT HANDLING & FEEDER 34 TRACK AND TRACE SOLUTIONS 36 COMPLETE ENGINEERING SOLUTIONS 38 SALES AND SERVICES 40

4 A GREAT EXPERIENCE IN PACKAGING IMA Industries BFB Division has a long tradition of designing and manufacturing end-of-line or secondary packaging machines. Our bundling and wrapping machines, case packers, palletizers and depalletizers cover a wide range of speeds and are aimed at the following markets: pharmaceuticals, cosmetics, food, tea, coffee and tobacco. Established in 1974, the company now employees 160 staff and is in the fortunate position of being the ideal supplier to multinationals, small laboratories and subcontractors. The reasons behind our success can be found in our extensive knowledge of the market and ability to provide customized solutions that cater for most of our users needs. The machines and feeder units are extremely flexible, enabling many types of product and pack to be processed. The constant flow of ideas generated by our close-knit team has resulted in a number of innovative concepts such as compact machine sizes, integrated packaging solutions, rapid size changeover and the handling of complex or non-standard products. A dedicated team of designers work on creating solutions intended to facilitate production and assembly, while cutting down on delivery times and installation costs. We pay particular attention to limiting the costs of manufacturing and maintaining the machines (life cycle costs), which results in higher profits for our customers. The machines feature a robust balcony structure and it is designed with the operator in mind. Simple to use and easily accessible, they guarantee maximum protection for both operator and product, at every stage of production. The number of size parts is kept to a minimum and size changeover is tool-free. Another equally important aspect is compact size which reduces the machine footprint and allows greater accessibility factors that give the machines a more contemporary feel. Attention to detail is an important part of our manufacturing philosophy. We also offer robotized, integrated cartoning and palletization systems that guarantee flexibility and efficiency in the increasingly demanding packaging market. 2

5 BFB DIVISION IS THE RESPONSE TO AN INCREASINGLY DEMANDING SECONDARY AND TRANSPORT PACKAGING TO PROTECT THE PRODUCTS. MORE THAN 6,500 MACHINES WORLDWIDE. 3

6 PHARMA The design and manufacturing standards applied to BFB Division satisfy the pharmaceutical GMPs, the same standards used by the IMA Group worldwide, and cover the full spectrum of end-of-line machines for large pharmaceutical lines. BFB Division machines are fully integrated with fillers and primary packaging systems and take into account specific controls in terms of quality, cleaning and safety, necessary in the pharmaceutical industry. There is also a need to offer solutions capable of guaranteeing high levels of manufacturing efficiency in a sector in which there is a growing demand for small batches and/or different pack sizes for the same product. This is where the speed of size changeover and straightforward end-of-batch reconciliation play an important role. Qualification packages of the equipments are available according to FDA/EMEA rules. The link-up of the single machines is expressly designed to reduce the overall length of the line and minimize the production wastage. BLISTER These products demand high production speeds up to 500 cartons/min. and the possibility of producing packs with a huge variety of dimensions and configuration. Configurations depend on distribution policy. BFB Division offers bulk or carton packaging solutions. TRAYS Often packaged in trays, both thermoformed or paper, glass vials, ampoules and syringes are very expensive, fragile products that demand special care, without forgetting the aspect of speed and variable pack sizes. BOTTLES The flexibility of BFB Division enables the processing of this type of product, whose shape can vary widely. Vials and bottles are often accompanied by leaflets or booklets with irregular shapes or which have to be positioned at a specific angle during the packaging process. 4 R15_Depl_gen_EOL_.indd 4 18/06/15 09:53

7 NON PHARMA Time to market is a primary concern for every company in this sector. BFB Division can provide rapid solutions that not only meet the needs of a highly dynamic market, but are also easy to add on to existing systems. The need to cater for consumer demand has resulted in a huge variety of product shapes and sizes, while the primary aim is still to preserve the integrity of the contents. The robust, reliable machines in the BFB Division range can process many different types of heat-seal film, paper or cardboard, every type of pack available on the market and can handle multiple product configurations. FOOD INDUSTRY CHEWING GUM AND CHOCOLATE Both these products are processed at high speed, but their form and composition tend to vary widely so that they require different treatment in each case. Chocolate, in particular, is sensitive to heat and high temperatures can cause alterations in shape, which is why special processing solutions have been developed, as is the case for chewing gum which can be processed either in cartons, bottles, stick packs or blisters in sleeves. TEA, HERBS, AND COFFEE BFB Division offers a wide range of secondary packaging machines suitable for wrapping individual packs, American-type card, wrap-around or trays. Together with IMA Tea & Coffee Division, the world leader in the primary packaging of tea, herbs and coffee, it provides complete lines able to work non-stop at high speeds. The machines are easily dismantled to enable thorough cleaning in environments that are often saturated with dust. COSMETICS Perhaps more than any other industry, cosmetics is a sector where creativity and new trends in design can be spotlighted with sophisticated packaging solutions. The use of hi-tech coated or scratch-proof surfaces make the packs extremely delicate, so that special care is needed during transfer, wrapping and packaging to prevent any kind of imperfection. TOILETRIES SHAMPOO Speed and flexibility in processing a huge variety of pack sizes are key elements for these products in a market that is highly susceptible to rapid changes in pack dimensions and shape. IMA BFB has the answer for the rapid processing of an enormous variety of products, even the most unstable shapes. SOAP Our machines, in particular the wrapping and bundling machines and case packers, have been designed to process this critical product without forgetting the speed factor. Another variant is the capacity to process unpackaged soaps that demand special attention when being transported to the packaging cycle, due to the loose materials it releases that can easily attach to surfaces. The machines have been designed with the operator in mind and can be easily accessed to enable thorough cleaning. TOOTHPASTES High speed lines are also a must for this type of product. BFB Division offers solutions for the processing of tubes, either loose or packaged in cartons. Special attention is paid to the reliability of the wrapping and handling of the carton. OTHER MARKETS The wide range of machine models and applications, together with robotized controllers which are fully integrated into the secondary packaging cycle, means that BFB Division can handle and process any type of product or pack. 5

8 SHRINKWRAPPING MACHINES MS 250 PP M/C MODEL MS 250 PP 60x30x60 360x210x160 (CYCLE/MIN) FILM WIDTH SHRINK WRAPPING AND STRETCH BANDING MACHINES BFB Division has been active in this sector since the 1970s and has acquired a great deal of experience in a sector where sealing is essential to guarantee secure wrapping. The fume-free cutting and sealing group is ideal for processing polyethylene (PE) while avoiding burning or blemishes. For bottles, aerosols or tubes wrapped in heat-shrink film, in the cosmetic and toiletry industries BFB Division offers a range of machines that can cover different speeds, with dedicated solutions for products whose shape tends to vary widely (or even supplied with a containing tray or into pucks). When it comes to pack banding, BFB Division offers a series of machines that are not only compact but also flexible and have a smooth, simple design, essential requirements in the pharmaceutical industry. The machines can always be combined with a heat-shrink tunnel with lower power consumption which are easily accessible and tend to avoid damage to the product. The positive conveyor system combined with precision at every stage of the production cycle enables high levels of efficiency to be achieved even with products that are awkward or hard to handle. 6

9 Extreme flexibility and clean design, compact footprint and excellent performance MS 250 A/AM/AP MS 250 B M/C MODEL (CYCLE/MIN) FILM WIDTH M/C MODEL (CYCLE/MIN) FILM WIDTH MS250A/AM 210/360x210 x x210x MS250 B 60x30x60 210/360x210x MS250AP 210/360x210 x x210x

10 SHRINKWR APPING MACHINES MS560 - T600 MS250 BLISTER STR/1 FILM WIDTH M/C MODEL (CYCLE/MIN) FILM WIDTH MS250Blister 35x30x60 80x95x / MS560EA 60x30 x60 220x210x BLISTER FEEDING WITH POCKETS BOTTOM ORIENTED BLISTER TWISTER 8 R15_Depl_gen_EOL_.indd 8 18/06/15 09:53

11 Extremely compact in-line collating for rectangular products or naked blister MS280 BAN MS280 EA PP - T600L (BUNDLE/MIN) FILM WIDTH (BUNDLE/MIN) FILM WIDTH MS280 BAN 60x30x30 180/210x MS280 EAPP 58x60x60 100x210x F D 6 Ø3 6 Ø7 0 m 0-Ø ax 7 E M/C MODEL b H= c a 9 R15_Depl_gen_EOL_.indd 9 18/06/15 09:53

12 SHRINKWR APPING MACHINES MS800 BAN + T800L M/C MODEL (BUNDLE/MIN) FILM WIDTH MS800 BAN 60x30x30 180/210x R15_Depl_gen_EOL_.indd 10 18/06/15 09:54

13 High speed machine specifically designes to handle bottles coming into pucks or individually MS800 MULTILANE + T800L M/C MODEL (CYCLE/MIN) FILM WIDTH MS800 50x130 x75 135x280x R15_Depl_gen_EOL_.indd 11 18/06/15 09:54

14 OVERWRAPPING MACHINES A50 M/C MODEL A50 30x25x60 220x120x320 MAX. SPEED FILM WIDTH H CUTTING LENGTH L 50/60 100/ /700 OVERWRAPPING MACHINES BFB Division has always focused heavily on these specific processes and has created specific film winding, conveyor, cutting and sealing systems to ensure that the film is always cut with a geometrically precise fold and sealed without wrinkles, air bubbles or other blemishes. The flexibility of these machines enables transverse sealing underneath the bundle or lateral sealing. The conveyor systems are compact with smooth surfaces and have been designed specifically to avoid slowing down or damage to the product. Our wide range of wrapping machines can process any type of pack, film or paper, even on products with irregular shapes. As for banding machines, BFB Division includes feeder and conveyor modules based on the positive transport concept, guaranteeing high efficiency even with unstable products. ceutical machines can perform rapid size changeovers and can also process large bundles at high speeds. In the cosmetic and food industry, however, special care is required to not to damage the product during the sealing operations. Special kits have recently been introduced to handle special films expressly required by the cosmetic industry. Rapid size changeover is assured due to the modular design and reduced number of parts. 12

15 A glossy touch on your products A100 A100AB M/C MODEL MAX. SPEED FILM WIDTH H CUTTING LENGTH L M/C MODEL MAX. SPEED FILM WIDTH H CUTTING LENGTH L A100 30x25x60 220x120x / /700 A100AB 30x25x60 220x120x275 60/80 100/ /700 C B A Ø Max. 13

16 OVERWRAPPING MACHINES A100HS SERIES M/C MODEL MAX. SPEED FILM WIDTH H CUTTING LENGTH L M/C MODEL MAX. SPEED FILM WIDTH H CUTTING LENGTH L A100HS 85x40x x120x / x23x60 125x90x SC 40x15x60 125x90x x23x60 175x90x

17 3721 SERIES 3711 LM M/C MODEL MAX. SPEED FILM WIDTH H CUTTING LENGTH L M/C MODEL MAX. SPEED FILM WHIDTH H CUTTING LENGTH L 3721 AM/ABV 3721 EP 65x23x60 300x150x220 60x25x x100x LM FAST 3711 LM HS 65x25x75 120x135x280 65x25x75 120x120x /1 75/2 50/3 36/4 110/1 100/2 70/3 50/ LA 40x25x75 120x90x / B C A E F D B A C L H ø MAX. 300 ø LA=1 layer only LM=Max 4 layers 15

18 OVERWRAPPING MACHINES M/C MODEL MAX. SPEED FILM WIDTH H CUTTING LENGTH L M/C MODEL MAX. SPEED FILM WIDTH H CUTTING LENGTH L 3703 BP 60x23x60 260x100x A 25x15x60 140x50x / A 60x23x60 260x130x E 45x15x60 80x50x /

19 A geometrically precise folded film, sealed without wrinkles, air bubbles or other blemishes. AF60 AF60E M/C MODEL (CYCLES/MIN) FILM WIDTH H CUTTING LENGTH L M/C MODEL MAX. SPEED FILM WIDTH H CUTTING LENGTH L AF60 60x25x60 360x170x AF60E 60x30x60 220x170x

20 TRAY PACKING MACHINES TRAY PACKING MACHINES BFB Division has designed and developed a vast array of popular solutions for packaging a product in a tray or display box while maintaining the same standards of flexibility and strength that characterise all of the Group s machines. Our extensive expertise in carton transfer, forming gluing and the high-precision movement of vials, cartons, bottles and other highly complex products caters for every sector of the market. Toploading models enable one or more products to be placed inside the same container, with the advantage that the end consumer can easily see the contents of the pack. TP60 M/C MODEL TP60 90x30x90 250x120x

21 Tray packing: a modern concept for an user-friendly packaging to consumer FR30/FR60 M/C MODEL FR30 90x30x90 250x120x200 30/60 OCV PREPRINTED BARCODE PRINT END VERIFICATION 19 R15_Depl_gen_EOL_.indd 19 18/06/15 09:55

22 CASE PACKING MACHINES SIDE LOADING CPM CP CPM 200x120x x400x400 - CP18 220x120x x400x350 8/10/14 CP28 220x120x x400x350 8/10 CP48 220x120x x400x620 8 G AT ER OP N NI NG R TU I RN TU ER OP SI OR AT OR SI PO OP DE TE SI DE LF SE AD V SI HE LT ME THO E TA PE 20 R15_Depl_gen_EOL_.indd 20 18/06/15 09:55

23 BFB Division has successfully developed various top and horizontal loading case packers: the ideal solution when there is a need for reliability, fast delivery times and last but not least, competitive prices. Our horizontal-loading case packers and their multiple applications are the result of ongoing technical developments intended to offer extremely compact solutions. The machines have a contemporary design combined with the balcony-structure principle and are manufactured according to the required speeds. Both servo-controlled vertical and horizontal loading case packers can process even the most unstable of products, such as toiletries, while maintaining high speeds. The case packers can also be integrated with banding or heat-shrink machines, that makes them extremely versatile and compact. The forming, transfer and closing systems can be applied to any type of carton, including thick card board or pre-cut carton that is then converted into shelf-ready packaging (SRP). CP38 - CP38/20 CP50 CP38 CP38/20 140x80x60 500x350x x80x60 500x350x350 20/30 20 CP50 120x80x x160x

24 CASE PACKING MACHINES SIDE LOADING Space is money and this is the reason why BFB Division has designed compact and very efficient machines taking up very little room CP18 + MINIFLEX CP18/28 + FLEX 2FPS CP18/28 + MINIFLEX 220x120x x400x350 5/6 CP18/28 + FLEX 220x120x x400x350 5/6 CP18/28 + FLEX 2FPS 220x120x x400x350 8/10 22

25 CP FLEX CP FLEX 200x120x90 500x400x350 MAX. SPEED 8/10 23

26 CASE PACKING MACHINES WRAP AROUND Versatile high speed wrap-around suitable to handle flat blank, tray and lid or american case (rsc) WA 30 WA 30 TRAY + INTERNAL LID WA x120x x300x WA30 TRAY 100x100x x180x

27 WA 30 BOTTLES + TRAY WA 30 TUBES + 4 FLEX WA 30 90x120x x300x WA x120x x300x R15_Depl_gen_EOL_.indd 25 18/06/15 09:56

28 CASE PACKING MACHINES TOP LOADING Wide range of solutions to cover different speeds and products CPV10 CPV15 CPV10 150x100x90 500x350x CPV15 190x80x90 600x400x

29 3754 SIZE GROUP H ( A+B) CPV Duplex 125x90x100 Duplex 230x165x270 Simplex 125x100x80 Simplex 500x400x /30 25/30 CPV20 150x100x90 520x400x DUPLEX FRONT REAR FRONT FRONT REAR HEAD REAR REAR HEAD SIMPLE HEAD HEAD FRONT REAR REAR REAR REAR 27

30 CASE PACKING MACHINES TOP LOADING Space is money and this is the reason why bfb division has designed compact and very efficient machines taking up very little room VERTICAL CARTOPALLET VERTICAL CARTOPALLET 200x120x x400x400 MAX. SPEED 7,5 28

31 VERTICAL CARTOPALLET VERTICAL CARTOPALLET 200x120x x400x400 MAX. SPEED 7,5 29

32 PALLETIZING STAND ALONE MACHINES Available in several versions ranging from basic applications such as manual pallet loading up to more sophisticated solutions such as automatic feeding of empty pallets and unloading of full pallets, the IMA BFB palletizers all have a solid structure and use precise, rapid multi-axis robotized systems for accurate positioning of products on pallets or inside big boxes. The machines are highly versatile, enabling the automatic palletization of regular slotted cases (RSC), half slotted cases, containers with special flaps or pre-assembled display cases. Any type of cardboard can be used. There are also optional add-ons such as ink-jet marking, weight control or glue-sealing modules. Solutions have also been developed that will centralise the palletization of different products from various lines. 4 FLEX 4 FLEX PALLET SIZE (MIN) PALLET SIZE MM (MAX) 800x1200x x1200 x cycles 30

33 MICROFLEX MINIFLEX PALLET SIZE (MIN) PALLET SIZE MM (MAX) MICROFLEX 800x1200x x1200x MINIFLEX 800x1200x x1200 x cycles 31

34 PALLETIZING STAND ALONE MACHINES Total synchronization and high efficiency guaranteed 2FPS FLEX PALLETIZER 2FPS 800x1200x x1200x FLEX-PALLETIZER 800x1200x x1200 x cycles 32

35 DEPALLETIZING MACHINES BFB Division has developed a robotized depalletization system for different products like vials jars and bottles positioned in heatformed trays. All the depalletizers have safe, easy access while incoming and outgoing expulsion is managed by a controlled-speed conveyor system. Depalletization is controlled by an integrated system that recognizes the position of the trays vision, and the overlapping and direction of both trays and vials. During transfer, the vials can be angled with high precision, rotated through 90 and adjusted up to 45. IMA Safe Line depalletizers can be inserted at the start of a packaging line or as an intermediate unit. DEPALLETIZERS MAX. SPEED DE-PALLETIZER 800x1200x x1200x DETAIL B DETAIL A DETAIL B DETAIL A BUFFER EJECTION EMPTY FULL R15_Depl_gen_EOL_.indd /06/15 09:56

36 PRODUCT HANDLING & FEEDER BFB Division has developed machines capable of handling unstable products, like tubes and roll-ons, and of feeding packaging machines like cartoners or systems to load plastic trays TLS (VERTICAL) TLS ø17x50 85x180x

37 TLS TUBES TLS ROLL-ON TLS TUBES ø30x90 ø60x TLS 47x R15_Depl_gen_EOL_.indd 35 18/06/15 09:56

38 TR ACK AND TR ACE SOLUTIONS TRACK AND TRACE ON BUNDLES: STAND ALONE TRACK AND TRACE ON BOTTLES: SHRINK WRAPPERS, VERTICAL CASE PACKERS AND PALLETIZERS 36 R15_Depl_gen_EOL_.indd 36 18/06/15 09:57

39 OPTIONALS TRACK AND TRACE ON BOTTLES: VERTICAL CASE PACKERS AND PALLETIZERS TRACK AND TRACE ON CARTONS: HORIZONTAL CASEPACKERS AND PALLETIZERS 37 R15_Depl_gen_EOL_.indd 37 18/06/15 09:57

40 COMPLETE ENGINEERING SOLUTIONS There are many optional units that can be combined with our end of line machines. The ones listed below are the most popular. The team at BFB Division is at your disposal to advise you on other solutions and any new requirements you may have. SHRINKWRAPPING Electronic stacking device Shrink tunnel installed as an integral part of the machine Product exit transport device for instable products Automatic film splicing unit Wheels for machine displacement Product discharge in case of power fault Bar code reader and carton ejection with the wrong bar code Engraver for dry or ink coding Product by-pass OVERWRAPPING Tear tape application Film print registration unit Reel trimming unit On edge transversal sealing Film perforation Additional reel holder Automatic film splicing unit Adjustable folding plates Leaflet insertion Lateral sealing belts Option for Kraft Paper Electronic film unwinding device and scissor knife Wheels for machine displacement Product by-pass TRAY PACKING Product presence control and positioning by means of camera Leaflet insertion Inkjet printing and data verification Tray rejection at discharge Closing with glue or tuck-in CASE PACKERS Product loading control by means of camera Case labelling and label printing verification Case rejection at discharge Case overturning at discharge Possibility of tape application all around the case Case magazine extension Outfeed case tipping system Closing by glue Track & Trace PALLETIZERS Empty pallet magazine Interlayer magazine Empty/Full pallet transport unit Product pick up by means of lateral grippers. Connection to driven vehicles or roller conveyors. DEPALLETIZERS Customized solutions 38

41 BFB Division has the most comprehensive range of secondary packaging machines currently available on the market and cannot be matched by any other supplier. We can provide stand-alone machines or complete lines to cater for specific requests in any industry. BFB Division takes care of every stage of the project: submission of a quotation, preparation of layout, engineering, calculation of conveyor and buffer systems, connections, customised design of specific units on request. The project management is also taking care of the preparation of all documents required for the internal tests such as pre F.A.T and F.A.T, customer qualification and S.A.T, including post-delivery assistance, specific training or inspection. A specific team of product managers look after all the engineering activities necessary to the development of the project; a constant dialogue with the customer is the key for a long lasting relationship. YOUR SUCCESS IS OUR SUCCESS BFB DIVIsion organizes specific staff training (certificate issued at the end of the course) in order to give the customer the possibility to achieve the maximum efficiency in the shortest time. The courses not only cover the functioning of the machine but also include practical aspects and daily operations such as size changeover, routine and special maintenance, troubleshooting, cleaning, quality control and other functions. ADVANTAGES Efficiency increase Shorter change over time Faster error analysis Preventive maintenance 39

42 SALES AND SERVICES IMA UNDERSTANDS THE NEED FOR EXCELLENT SERVICE AROUND THE WORLD The use of original spare parts since they are essential to guaranteeing perfect machine working order over time, full production efficiency and life cycle duration. Spare parts can be ordered from IMA directly or alternatively via the MyIMA e-commerce system and shipped to you within hours. Present in over 70 countries 10 branches providing sales and service More than 50 representing agencies 90 technicians from Italy supplying worldwide service 50 technicians from local subsidiaries and agencies 11 after sales supervisors IMA provides prompt and effective technical assistance which covers the entire life cycle of its equipment. This assistance is provided by a dedicated team of experts able to meet our client s needs on a day to day basis. A customer oriented after sales service staff is what distinguishes IMA from the rest of the world. 40

43 For information on the IMA subsidiaries and sales offices, visit our website: (contacts section) 41

44 January F IMA S.p.A. reserves the right to make any changes to the described machine characteristics. IMA S.p.A. IMA BFB Division Via Romagnoli, Bentivoglio (Bologna) - Italy Phone Fax imaeol@ima.it