Integra 520V, the new robotized integrated blister line able to package 520 blisters and 500 cartons per minute
The machine with balcony design is a mere 10 meters long, so very compact, and it combines two machines: a thermoformer (520 blisters/min in Alu+PVC/PVDC/PET/Alu/other materials) and a cartoner (500 cartons with tuck-in or glued flap closure and various other combinations). This new model features not only the innovative functions of Integra 320, but also new pushers, a drum-type carton opener to deal with high speeds and a new leaflet pick-and-place system. The final result is an ideal machine for single-blister cartons.
Technical features - THERMOFORMING SECTION
Material feeding and blister lidding
The reels of forming material are arranged in a compartment at the back of the machine, but can also be installed at the front of the machine. Reel unwinding is automatic, servo-driven and stops when the film runs out. The lidding reel (maximum diameter 300mm) is located at the front of the machine and this too has an automatic splicing table.
Pre-heating and forming
The thermoforming station is arranged at the back of the machine. The material is formed in three different ways: by compressed air for PVC, PVDC and ACLAR, by air and plug assist for difficult-to-shape plastic and by a purely mechanical solution of forming dies for aluminum.
A servo-driven transfer roller positions the forming material correctly for the infeed stroke, which is adjusted automatically without the use of tools.
The machine can be equipped with different product feeders: High Speed feeder with patented release system by Pulsar, Universal and Multiplex. Its feeding station can accommodate two different loading systems in the same area: Universal+HS or Multiplex+Universal.
The flat sealing station works with combined intermittent and continuous motion. It seals even at low temperatures, by extending the sealing time and keeping the sealing pressure uniform over the whole surface area of the blister. Cooling plates cool the web just after sealing.
Product presence and web pull are checked by several cameras installed along the line.
Coding, cutting, perforation and outfeed
The blisters are coded by cold punches and cut in the same station. The perforating station is an optional. Once cut, the blisters are picked up and placed directly onto the conveyor belt of the Robocombi. The waste is discarded into separated containers.
The three-axes Robocombi robot feeds the blisters into the bucket belt of the cartoning machine and can be programmed for different stacking heights, based on the preset blister count and is managed by automatic synchronization software of the transfer, tracking and stacking system.
The two sections of the line (blister thermoformer and cartoner) can work separately.
Carton magazine is arranged under the product conveyor belt in order to avoid dust over the blisters and to ease carton loading for operators. Drum that picks up the cartons and opens them out, holding them firmly and accurately even at high speeds. The cartons are then taken directly to the carton conveyor belt. The carton conveyor belt is silent, even at high speeds, and is very easy to keep clean. The leaflet-feeding unit is enclosed by guards to minimize noise. The GUK feeding unit is in an ergonomic position (lower than the previous models) to ease leaflet loading. In view of the high processing speeds involved, a new rotating pick-and-place unit has been designed and installed to transfer the leaflets to the pushers. Product insertion unit “Cinquecento”: two separate combined units, pusher and blade, insert the product into the carton precisely, even at high speeds. A simple input from the display will rise the unit automatically when the machine has to be cleaned or serviced. The machine is designed to handle all kinds of carton closure.