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26 packaging There is a definite trend towards tetraeders again. The ContiBag produces 100 of these packs per minute with the transverse sealing station developed specially for tetraeders. Standard packs can be produced on this machine as well if required by changing the dies. 50 different pack shapes. The requirements of both series – not only ContiBag but also FlexiBag – were satisfied by the FFS machine technology package from Elau. Faster start-up The modular program structure and new technology package include many available function modules. A number of functionalities for each function module facilitate programming for the machine manufacturer. The functions ‘Infeed conveyors 1 to n’, ‘Product collation’, ‘Weighing unit’ or ‘Auger metering unit’ are, for example, available for the function module ‘Product infeed’ for vertical or horizontal FFS A uniform program structure, which has proved its effectiveness and is not changed constantly, is essential as a strong foundation for the user program machines. So many modules have already been programmed in advance. The machine manufacturers therefore generally need less than one month to create a standard program for their own machine models. Startup takes less than one week and new customer-specific requirements can often be met in less than one day. Diagnostics can be carried out directly on the control unit. This means that all the system data and system faults are displayed to the user in the branded goods industry via the HMI. This transparent service information minimises machine stoppage times. Remote diagnostics via teleservice are also integrated as standard. Andreas Hollmann had this to say about implementation, “The FFS machine technology package solves the problems of axis synchronisation and sealing element pressure control. Our experience to date has shown that it is likely to be possible to shorten the time required for program start-up by 50%.” Central control concept for all output levels The FFS machine technology package from Elau meets the requirements of all FFS machines, whether they are vertical or horizontal, continuous or intermittent with speeds of up to 250 cycles, highly flexible and complex or not. A central control concept is the better solution for modular machines in particular, because modularity is only implemented in software. This means that additional interfaces are not needed. They would merely make the solution unnecessarily complicated and restrict system capacity. “A uniform program structure, which has proved its effectiveness and is not changed constantly, is essential as a strong foundation for the user program,” explains Elau Application Manager Dietmar Hamberger. “The central automation approach of PacDrive is absolutely right for machines with exacting motion requirements. With the FFS machine technology package, we have now proved that central, scalable automation technology is suitable for machines of low and average complexity, as it supports the modular approach better than any other system architecture. We implement the modularity in Elau will be presenting a robot technology package at Interpack software to avoid unnecessary interfaces,” says Dr Thomas Cord, Elau Research & Development Manager. Elau will be presenting a robot technology package at Interpack. The package is just as suitable for 2-axis articulated-arm robots as it is for 3-axis gantry, 2-axis delta, 4-axis Skara or portal robots with two, four or seven axes. Further technology packages are in the process of being prepared. ■ Marco Rüb Corporate Communications Elau AG www.elau.de food spring 2005
packaging 27 Coated film gets rid of moulds and microbes Film-packaged foodstuffs often contain added preservatives such as benzoic or sorbic acid, but it is clearly better to have as few additives as possible in food. This is why scientists at the Fraunhofer Institute for Process Engineering and Packaging IVV, have opted for a different way of getting rid of moulds and microbes. Instead of adding preservatives to the food, they coat the packaging film with them. How it works Any type of flexible foil can be varnished without affecting its basic properties (moisture or oxygen barrier). A layer containing anti-microbial activity can then be applied as an additional feature. From a technical point of view coating is a simple, well established process, and no special devices have to be developed. The only special component is the composition of the coating, consisting of a carrier material and anti-microbial additives. The carriers have to provide proper adhesion and sufficient release of the active agents; and can be either ORMOCERS, inorganic/organichybride ploymers developed by the Fraunhofer Institute for Silicate Chemistry in Würzburg, or a special composition of organic polymers under development. The coating process is simple, and in the Institute’s pilot plant a reel process is used. The film passes a coating station followed by a drying device (UV-curing in the case of ORMOCERS). The main challenges were to discover active substances with suitable release behaviour that were food-compatible (benzoic or sorbic acid) and to scale up the transfer of the coating process from laboratory scale to industrial scale. The Institute is still working on the latter challenge. Applications The film costs only marginally more than normal film, as the components are inexpensive, and it can be used for all types of solid food where the film directly covers the food surface. Since it is only the contact surface that is protected by the small amounts of released active agents, it cannot be used for liquid food or beverages. In the case of liquids the food preservatives would not remain on the surface but would spread through the entire product and be heavily diluted. The main applications will therefore be for fresh meat, meat products and cheese. And if applied in a strictly hygienic environment, it may obviate or reduce the need for complete preservation of the foodstuff. The advantage to the consumer is that they get food that contains fewer preservatives, About the Fraunhofer-Gesellschaft The Fraunhofer-Gesellschaft undertakes applied research of direct utility to private and public enterprise and of wide benefit to society. Its services are solicited by customers and contractual partners in industry, the service sector and public administration. The Fraunhofer- Gesellschaft maintains roughly 80 research units, including 58 Fraunhofer Institutes, at over 40 different locations throughout Germany. A staff of some 12,500, predominantly qualified scientists and engineers, works with an annual research budget of over one billion euros. Of this sum, more than 900 million is generated through contract research. Roughly two thirds of the Fraunhofer-Gesellschaft’s contract research revenue is derived from contracts with industry and from publicly financed research projects. The remaining one third is contributed by the German federal and Länder governments, partly as a means of enabling the institutes to pursue more fundamental research in areas that are likely to become relevant to industry and society in five or ten years’ time. The Fraunhofer-Gesellschaft is also active on an international level: Affiliated research centres and representative offices in Europe, the USA and Asia provide contact with the regions of greatest importance to present and future scientific progress and economic development. and the industry and retailers benefit from better shelf life and quality Possible future developments Future developments may include coating by spraying to fit containers. Also, hydrogen peroxide treatment is currently used in packaging materials for cold sterilisation and aseptic packaging, but the process does not seem to be residue-free. It may be that in the future, antimicrobial coating could replace hydrogen treatment. ■ Dr Dieter Sandmeier Fraunhofer Institute for Process Engineering and Packaging IVV www.fraunhofer.de food spring 2005
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