Denestech Ltd, Experts in Denesting, Lidding, Pick & Place, Leaders in Denesting Technology

Typical Applications

Denesting into a Flow-Wrapper/HFFS

Automatic Denesting and synchronisation of trays directly into any Flow-Pack machinery or indexing conveyor.

TrayFlow feeding a Flowpack machine

Inbuilt intellegence

The TrayFlow Tray Denester is the perfect partner to any Flow-Pack machine or indexing conveyor. Inbuilt technology allows the TrayFlow Denester to automatically follow the in-feed of the flow-pack equipment, matching speed and position. Furthermore, it does this without the requirement for encoders or other complex equipment. The TrayFlow Tray Denester adjusts its speed and denesting position perfectly to match that of the host machinery even during acceleration, deceleration or stopped conditions. This scenario where the Denester is 'aware' of the circumstances relevant to its operation enables the Denester to run optimally at all times, improving the overall reliability of the production line, and also minimising wasted energy  whilst maximising the service life of the machinery.


The modular nature of Denestech Machinery means that integrating your TrayFlow Denester couldn't be easier. We manufacture a range of mounting frames designed for different types of installation. This allows easy and accurate positioning of the equipment in almost any scenario.

Denesting on to a conveyor belt with accumulation

The TrayFlow Tray Denester, Denests trays on to a flat belted conveyor at the exact maximum speed that demand requires, which is set/displayed on the control panel. 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.

TrayFlow 300 Denester Application

Denesting Containers for Automatic Filling

Typical application of a TrayFlow Denester denesting containers on to a conveyor where the container is automatically filled with product as it passes beneath the depositor of Multi-head Weighing equipment. The Denester feeds the containers on to a flat belt at a fixed rate. Containers pass below the depositor as a photo-electric sensor detects the presence of the container at the fill point. Products are released into the container without the requirement to stop the container. Denesting rate may be set accurately at the denester control panel. Run/stop controls for denesting may be managed remotely by an operator or master machinery.

Denesting for manual loading

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 not uncommon for the loading of the trays to be automated, allowing the complete process to be supervised by a single operative.

Direct Lid Placement

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.

Denesters - Pick and Place Machines - Pot droppers - Foil Placers and Dispensers - Card Placers
Complete De-nesting solutions for today's requirements of environmentally friendly packaging products