Technical Documentation G.Mondini S.p.A. Tray Sealer TRAVE-350
Tool sizes are 340 mm in width and 570 in length, number of trays per tool can be maximum 4
according to the tray dimension in travelling direction. Sealing tool driving system and sealing force
generator consist in a fully electro-mechanical system.
General description.
Tray in feed.
A belt is receiving the trays from a previous
conveyor. Trays have to arrive aligned and at a
suitable distance. A smart belt will pace and group
the trays, independently of the previous pitch, to
prepare them to be transferred to the sealing
station. These two belts can handle random feeding
speed and allow the machine to remain in stand by,
which is important, both for fully automated
solutions and for manual operations. Detection of
the tray is provided by a single photo eye
positioned above the travelling plane.
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Technical Documentation G.Mondini S.p.A. Tray Sealer TRAVE-350
Tray handling.
To avoid tray shaking and excessive
deceleration and acceleration of the product
inside the tray, the handling is extremely
smooth and accurate.
Trays are moved from the smart belt to the
sealing station through moving arms, which are
gripping the group from the side. These arms
are controlled by a servomotor system, whose
main characteristics are smoothness, high speed,
consistency, accuracy and extremely low
maintenance and by a long-stroke pneumatic
piston for the rotation to allow a very good
smoothness and a wide range of settings.
Film unwinding and waste rewind.
Film saving and reliable continuous run are at
the base of the development of the system
incorporated in this tray sealer. The reel is
positioned on a cantilever shaft which is
connected to a servomotor. Film is kept in
tension through several shafts, which are
supported both sides to avoid any misalignment.
A dancing bar keeps a constant tension on the
film during the unwinding.
The film is pulled through the tool via two
counter rotary rollers, controlled by an electrical
motor, which allows smooth pulling to reach the
maximum waste savings. A clutch controls the
tension on the continuous running film waste
rewind.
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Technical Documentation G.Mondini S.p.A. Tray Sealer TRAVE-350
Sealing Station.
Once the trays are positioned in the sealing tool,
the lower part is raised and the sealing process
starts. High sealing force and consistency of
sealing parameters are critical to guarantee the
same seal characteristics tray after tray. The
TRAVE-350 is equipped with a high duty system
which is of an electromechanical type. A rod-crank
system is controlling the motion up and down of
the sealing tool, keeping an absolute control of the
tool position while still very fast. The sealing force
can reach 2200 Kg. Main characteristics of this
solution are smoothness, high speed, very high
consistency in sealing force, very high accuracy in
positioning and extremely low maintenance.
Tooling.
Each tray foot print has its own tool, but different
tray heights are handled in the same tool.
The construction is completely in anodised
aluminium and all parts are machined from a single
piece to reach the best accuracy in sealing pressure
distribution. Each tray cavity supports the base of
the sealing edge with a T section gasket to recover
from different thickness in the packaging material.
The location of the tray is as accurate as possible,
due to tray size consistency, to reach the best
results in seal location and film trimming. Sealing
plates are made of aluminium-bronze, to keep the
sealing temperature consistent in all contact points,
the sealing profile varies according to the specific
packaging material, it also contributes to remove
contamination from the sealing area. Heating is
provided by an element cast into aluminium. This
solution provides a long lasting heater plate and a
very accurate sealing temperature control: plus or
minus five degrees between each point.
Out feed.
A policord belt takes the sealed trays out of the
guarding in a straight line.
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Technical Documentation G.Mondini S.p.A. Tray Sealer TRAVE-350
Wash Down capabilities
Clean ability and resistance to continuous wash
down is one of the main characteristic of this
machine.
Hygiene Design.
Avoidance of contact between extended flat surfaces.
No closed cavities which can trap water and dirt.
No sensors below travelling plane.
Reduction of exposed nuts and bolts to increase easy cleanable surface.
One main electrical cabinet and one main mechanical cabinet.
Food grade materials.
Stainless steel for main body.
Anodised aluminium tool.
Belts in polyurethane.
IP Rate.
IP 65 mechanical cabinet.
IP 65 electrical cabinet.
IP 65 pneumatic and services cabinet.
IP 67 control panel.
IP 67 control switches.
IP 67 photo eyes with quick release for quick substitution
IP 67 proximity sensors with quick release for quick substitution.
Operations.
Start, Stop, Reset, are simply controlled with standard and user friendly switches. All other settings
are controlled via panel control. In this way the operators are free to use the machine without the
risk of changing parameters which can jeopardize the efficiency. The list of parameters which are
menu driven are:
Sealing Temperature.
Sealing Time.
Vacuum Time (optional).
Gas Time (optional).
Film Unwinding Speed.
Length of film, by time.
All previous parameters are stored into recipes to allow an easy and fast change over. Increased list
of parameters are due for automatic lines.
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Technical Documentation G.Mondini S.p.A. Tray Sealer TRAVE-350
Change Over
A full change over of the tray sealer can be done in ten minutes. All parameters are menu driven, in
this way the skill requirement is very low. Both bottom and top tool slide out of the chassis of the
machine. The top and the bottom tool are locked and unlocked through a pneumatic quick release
system. No lifting is required by the operators.
Performances
The product and the packaging material will determine exactly the cycle time. However, as a
reference, we consider the following table of cycles per minute.
Type of Product Heat Seal Pre Cut Lid V&G G Closure L Closure
Solid
Liquid
17 15 14 17 16
10 10 8 10 10
Maintenance
Being mainly a mechanical machine, all bearings, bushing, shaft etc need to be greased regularly.
Each tool has its own greasing point.
Mechanical Specifications
Electrical Motors: Coel.
Gear Box: STM
Drum motor: Interrol
Belts: Habasit
Pneumatic Specifications
Metalwork
Health and safety
The machine is CE marked and comes with declaration of conformity.
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Technical Documentation G.Mondini S.p.A. Tray Sealer TRAVE-350
Electrical Specifications.
Mondini Standard
Plug sockets (auxiliary v.220) Schuko
Main switches Merlin Gerin / Schneider
Push button ,Selector 22.5mm Telemecanique / Schneider
Signal lamp 22.5 mm Telemecanique / Schneider
Interface relay Phoenix / Omron
Emergency stop safety relay Telemecanique / Schneider
Feeding device 24 v.dc Telemecanique / Schneider
Protective relay for motor Telemecanique / Schneider
Frequency Inverter B&R
Terminals Phoenix
Temperature controller B&R
Bus system I/o
X2X-POWERLINK
Axis communication POWERLINK
Multi-polar plug connectors Ilme
Opto-electronic sensor Wenglor
Proximity switch Telemecanique / Schneider
Safety switch AB Rockwell
Temperature sensor PT 100
Acoustic alarm units Telemecanique / Schneider
Signal tower Telemecanique / Schneider
Plc B&R
Operator panel B&R (PC) G.Mondini
Axis control B&R
Axis motor B&R
Driving unit per Item
Infeed belt
Grouping belt
Exit belt
AC motor
Optional : Inverter (with variable speed controlled by panel)
AC motor
Standard : Inverter (with variable speed controlled by panel)
AC motor
Optional : Inverter (with variable speed controlled by panel)
Arms translation SM motor
Arms closure PN
Tool lifting movement AC motor
Film feeding SM motor
Reel unwinding
AC motor
Optional : Inverter (with variable speed controlled by panel)
Asynchronous motor AC motor
Servo motor SM
Pneumatics PN
Not applicable NA
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Technical Documentation G.Mondini S.p.A. Tray Sealer TRAVE-350
TRAY SEALER OPTIONS
Vacuum & Gas
This option allows the production of modified atmosphere packs. It includes:
Vacuum Pump: Busch 300 m3.
Vacuum hoses and valves Gemu.
Gas reservoir.
Gas hoses and valves.
Vacuum and Gas tool. The vacuum chamber is machined out of a single piece of
aluminum to reduce the risk of leakage. Also all seals are lip seals type and greased
with vacuum type grease. The minimum pressure reachable is below 4 mbar. These
results are important to decrease oxygen residuals and to increase productivity.
PLC software.
Anti-explosion pump
It is mandatory whenever using high oxygen flows or gas mixing and the machine is sold with a
vacuum pump.
High oxygen protection
All the vacuum valves and gas valves are provided with proximity sensor for positive detection of
status (open and closed). A PLC which is separate from the main one checks that the vacuum and
gas system is working properly for each cycle, avoiding a flow of missing gas to the vacuum pump.
In case of malfunctioning the machine detects it and goes in a state of alarm.
Note: this system is not certified and it will be totally under the responsibility of the end user
to be provided with suitable pumps for the type of product to be packed.
Pressure transducer
The vacuum and gas cycle is controlled through timers but the pressure transducer will detect the
level of the millibar at the end of the vacuum cycle and the gas cycle. If the readings are not
between the boundaries pre-set in the recipe, the machine will go into a state of alarm. Also with the
specific menu the machine will close the tool, pull the vacuum to the maximum level and then hold
it. Through the readings again it is possible to see any leakages in the tool.
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Technical Documentation G.Mondini S.p.A. Tray Sealer TRAVE-350
By-pass belt
By-pass belt suitable for allowing un-sealed trays
to pass through the sealing station without being
heat sealed. The by-pass belt is positioned in the
place of the sealing tool where there are trays
which have to by-pass the sealing station.
Pre Cut Lid
A shuttle system allows the machine to pick pre cut
lids from the side magazine located on the side of
the tool.
This option includes:
Shuttle structure.
Vacuum generator.
Hoses and electro valves.
Tool with side magazine.
PLC software.
Printed Film Registration
A photo eye detects the marking log on the printed
film and stops it in the right position to have the
printing centred on the tray. An accurate film lay
out is provided for each tool to allow a proper film
printing.
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Technical Documentation G.Mondini S.p.A. Tray Sealer TRAVE-350
TOOLING & TOOL OPTIONS
Pre Cut Lid.
Lids are stored on the side of the tool. A pick and place removes the lids from the base of the pile,
or the piles, via suction cups, then position the lid on the sealing profiles. Suction cups retain the lid
in position. To use this tool the machine has to be predisposed with the pre cut lid shuttle.
Inside Cut.
This option allows the tool to cut the film inside of the perimeter of the tray. Such solution can be
used to:
Avoid film protruding the edge of the tray
To run cups or trays with protrusions or handles from round sealing profile,
without need of keeping them aligned.
To seal special tray with sealing surface below the maximum height of the tray.
No predisposition is required.
Alum Foil Crimping.
This tool cuts a lid from a reel of aluminium and crimps it around the tray. The aluminium has to be
at least 40 micron thickness. No predisposition is required.
Pre Cut Lid Crimping.
Pre-shaped lids are stored in a side magazine. A pick and place system removes the lids from the
base of the pile, or the piles, via suction cups, then positions the lid on the sealing profiles. Suction
cups retain the lid in position. To use this tool the machine has to be predisposed with the pre cut lid
shuttle.
Double heater plate.
In case of aluminium tray, to decrease the required sealing time and to reduce the sealing
temperature, which damages the lid, a second heater plate is positioned in the bottom part of the
tool. Sealing profile is heated from the top and the bottom, sealing time is reduced by half the time
compared to a standard solution. A water cooled bottom plate avoids the transfer of the heat to the
main machine body. The machine has to be predisposed to run two independent heater plates.
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Technical Documentation G.Mondini S.p.A. Tray Sealer TRAVE-350
Extra Equipment
Tool Trolley
Positioned to the side of the tray sealer,
assembled on wheels and locked in position,
the bottom and top tool can be transferred into
the trolley very easily. The top tool is
automatically secured in position once the
trolley is unlocked from the tray sealer. Now
the trolley can be taken to the maintenance
area. The top tool can be rotated up-side down
through a gear box helping a lot cleaning and
maintenance. Stainless steel construction.
Hidraulical Tool Trolley
Compared to the standard trolley, it has an
hydraulic levelling system.
For this reason it can be adaptable in height to
the different TRAVE and to the tool racks
avoiding to act on handle-wheels.
Two-sided tool trolley
This is a two-faced trolley with the possibility
to extract the tool from both right and left
handed machines. Asymmetric hooks avoid
possible matching errors between trolley and
machine.
Tool Rack
To easily accommodate the different tools a
tool rack, in stainless steel, is available. It can
also be equipped with wheels or pre heating
station.
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