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Typical Applications

Denesting into a Flow-Wrapper/HFFS (Fresh produce)

This example uses 6 pack Beef Tomatoes which are filled into denested trays and flow-wrapped at 60-80 packs per minute.

TrayFlow Tray Denester, AWETA Prepacker, Flow-wrapper.

6 or 8 pack tomato trays are Denested and synchronised directly into the flighted in-feed of a Flow-Wrapper. The empty trays pass under the load point of the AWETA Prepacker which drops rows of tomatoes into either side of the tray, filling the tray in a single operation. The filled trays, already travelling along the in-feed of the Flow-Wrapper are sealed and labelled then loaded directly into baskets for shipment to the supermarkets. This complete process may be supervised and maintained by a single operative.

Denesting and Lidding

TrayFlow or ServoFlow Denester, Conveyor, Manual or automatic fill/load, ServoFlow Lidder.

The TrayFlow or ServoFlow Denester deposits containers on to a conveyor which are transferred for filling. The containers once filled with product pass through the ServoFlow Lidding machine, which collects individual lids from it's magazine and applies them directly onto the container. The ServoFlow will apply the required force upon the lid to close the container completely in a single operation. The conveyor may be an indexing type or else each container may be stopped and released through each process by restraining devices at each station. The fully closed container passes out of the ServoFlow for coding and end of line packaging. A single operative is required to maintain and supervise the Denesting, Filling and Lidding processes.

Denesting for manual loading

TrayFlow or ServoFlow Denester, Conveyor, manual or automatic fill/load, Autosych Conveyor, Flow-wrapper.

Typical application of a TrayFlow Denester denesting trays on to a conveyor where the tray is manually filled with a product by production operatives. The Tray Denester satisfies the requirements for feeding empty trays to 4 product loading operatives by working intermittently at a slightly faster rate than is required and regulating the feed of trays in an 'on demand' basis. The loading conveyor is filled with a buffer line of denested trays which are monitored typically by use of a photo electric sensor, which feeds back to the Denester. The filled trays are fed from the loading conveyor and automatically synchronised into the flighted in-feed of a flow-wrapper for final wrapping. The Denester magazine is loaded and re-filled infrequently by the operatives. In this example, the production operatives are required for the loading of the product, however, it is common for the loading of the trays to be automated, allowing the complete process to be supervised by a single operative.

Denesting on to a flat belt with accumulation

The TrayFlow Tray Denester, de nests multi cavity trays on to a flat belted conveyor at a speed approximately 25% greater than demand requires. The speed of the denester may be set manually or may also use the conveyor speed as a reference, and automatically adjust to suit. The trays are accumulated on the belt and a photo-electric sensor detects when the queue of trays has accumulated to reach it's high level. The signal from this sensor is received into the Denester and de-nesting is automatically paused until the volume of trays accumulated is depleted to the point where the sensor detects that trays have fallen below the high level. Denesting is automatically resumed until the volume of trays is once again restored. This simple system works extremely efficiently and provides an automatic, on demand solution for applications such as biscuit or tea cake lines where trays are filled either manually by operatives or by an automated system. In either case, the product accumulated on the belt and the redundant capacity of the Denester guarantees that the supply of trays to downstream operators and equipment is uninterrupted.

Denesting into a Flow-Wrapper (Bakery)

This example uses Hot Cross Buns which are loaded onto folded base cards and flow-wrapped at 60 packs per minute.

ServoFlow Pick & Place, Manual loading, Flow-wrapper.

Flat, creased base cards are picked from the ServoFlow magazine and placed directly onto the flighted in-feed of  a Flow-Wrapper. The flat base card which already has an indented crease is pushed directly through a former before it's placement into the in-feed, which folds the card to it's required shape (either L,U or J), so the card arrives into the flow-wrapper fully formed. Buns are loaded manually onto each formed card, which already travelling along the in-feed of the Flow-Wrapper are sealed and labelled then loaded directly into baskets for shipment to the supermarkets. This complete process may be supervised and maintained by two operatives.