Interpack: 12-18 May 2011, Düsseldorf, Germany

INDEX

EDITORIALDear Reader,Welcome to the Interpack 2011 edition of PFM Lab which will bring you up to date witha whole spectrum of technical innovation from our group.Since the last Interpack in 2008 PFM Group companies have been particularly focusedon research and development, creating a comprehensive range of new applications thathave met and, in some cases, anticipated our customers’ increasingly demanding andspecific requirements.We have a lot to tell you, so much more than ever before, and are sure you will find ituseful.These are, of course, turbulent economic times throughout the world. However, theconsiderable experience of PFM over a broad sector of industry has helped reassurecustomers and we are pleased to have been rewarded with their confidence andbusiness.Innovation within the PFM group is a major factor in our success.Not only does this come from an unparalleled internal expertise but also from thenetwork of relationships built and sustained over many years between PFM Groupcompanies and the external professionals, suppliers and customers with whom wework.All have been a great source of stimulus and support.We have enjoyed creating this edition of PFM Lab. We hope you will share ourexcitement at the technology we are now able to present.Elisabetta FioravantiCEO PFM Group05

PFM Group: Interpack Special 2011Interpack 2011, Düsseldorf, from 12 to 18 May:PFM, SPS, MBP and BGPACK invite you to visit the PFM Groupstand where we will be demonstrating a series of dedicatedtechnological innovations for the flexible packaging industry.Pavilion 13, stand C15 D14. The 450 square metre stand will bewelcoming visitors from all over the world to see innovation withevery exhibit.06

2008 – 2011: Severity,Research and DevelopmentWith a turnover of 68 million Euros, a workforce of 280 employeesand over 1000 machines produced, 2010 came to a close with amultitude of technical innovations chalked up by all the companiesin our Group.This followed a positive response from all PFM Group companiesto the severe economic crisis, which coincided with a major decline inproduction in manufacturing industry over the period 2008-2009.They were able to diversify their range of products and repositionthemselves within new highly dynamic markets with no loss ofproductivity, turnover and business relations.For the last 10 years PFM has been ISO 9001-2008 certified whichmeans that every company section and process, including design,production, sales, and after-sales service pursue a policy based onquality, aimed at continual improvement in customer satisfaction.And it has been during this decade characterised by total qualitythat we have been in a position to draw on all the resources necessaryto cope with large scale investments in Research and Development.Just as the first signs of the crisis appeared we improved our machines,we designed and patented new models, we improved manufacturingprocesses by making them more efficient and competitive, we putafter-sales service high up on our list of priorities and placed dozens oftechnicians around the world to assist our customers.Our enthusiasm for custom applications demonstrates all the skilland experience in both technical and business areas available withinthe group. It is also the result of commitment to communication withcustomers, to understand their requirements and find solutions to theirspecific problems.The year 2011 has started well with a good flow of orders and theinauguration of the new SPS headquarters in Bogogno (Novara), withof 6000 m² of production space and 2000 m² of offices.A further major event is the inauguration of PFM Iberica which hasbeen created to allow PFM to operate at the heart of this strategicallyimportant market. There has been a boost in the activity ofPF Meccanica, the company that provides the others in the Group withprecision components and this has had a positive effect on quality andreliability.Our companies will continue to innovate in order to gaincompetitiveness and to move market focus from competition basedon price to competition based on value.Paolo FioravantiManaging Director07

PFM Group: Strategies forGrowth in Times of CrisisRather than take a defensive position in a time of economicdownturn PFM preferred to invest in quality and innovation.We looked closely at special applications and developed new technicalsolutions to enhance performance levels while a strategy of researchand development saw the arrival of new products, completelyinnovative and patentable.Over the past three years PFM Group has consolidated its presenceon the traditional European, North American and North African markets,expanded its client portfolio to include the largest international brandsand has reached out to the more distant, developing countries.Now, in 2011, the PFM Group is the principal supplier to thecheese packaging industry, and has successfully introduced innovativeresealable packaging solutions. At the same time we have increasedour share in the whole and fresh-cut fruit and vegetable market byoffering technology for the challenging ready-to-eat fruit and fruitsalad market sector.We have also experienced exponential growth in the bakery andconfectionery sector where we offer complete turnkey solutions.We are going strong in Modified Atmosphere Packaging of foodproducts and have become a major player in the market for completefeeding and packaging lines to handle wet wipes and cosmetics.PFM’s position in specific segments of the international flexiblepackaging market has also been strengthened by our strongcommitment to innovation, continual motivation of a robust salesnetwork in all major countries of the world, strengthening of our preand post sales service, and efficient cost control.As a result, our sales force has been able to demonstrate the clearcustomer advantages of comparing machinery by the added valueoffered, rather than simply price alone.Our vehicle for innovation is very much based on almost half acentury of solid relationships with our customers. These relationshipshave given us a powerful identity, a strong image that is based on thecapacity to take on and maintain commitments with our partners andcustomers, an image that has become a success factor for attractingnew customers.Andrea FioravantiR&D and Sales Director08

QUALITY, the Heart of our CompetitivenessIn 2002 PFM Packaging Machinery SpA, the headquartersof the PFM Group, achieved ISO 9001-2000 certification,subsequently updated to ISO 9001-2008, by DNV: one ofthe principal certification bodies in the world.This highly coveted milestone marked a significant pointin the company’s programme of continuous improvement,aimed at its main objective: maximum customer satisfactionexpressed in terms of product and service.PFM utilises the ISO 9001 – 2008 system for qualitymanagement of all corporate organisational processesincluding the definition of customer requests, design,machine assembly and testing, and full customer service.All stages of organisation are co-ordinated and managed bya team of professionals who receive ongoing training andare provided with the very latest equipment.Products are designed by a multi-disciplinary technicaldepartment utilising structural analysis and three-dimensionaldesign software. Utmost care is taken with machine assemblyand testing which lays solid foundations for the servicedepartment which, at any one time, has dozens of specialistservice technicians scattered around the globe.In the three years from 2008 to 2011 completecomputerisation of the quality system made it possible forus to have immediate and absolutely precise feedback onindividual processes. As a result, we were able to targetimprovements in both internal and external operations, withspecific demands for quality from our suppliers contributingto increasingly higher levels of reliability for customers.Our objective is to maintain a culture of continuousimprovement in order to achieve maximum customersatisfaction. To achieve this we expect to establish acontinuous relationship with the customer by involving himin each step of the process, working together to create notjust a reliable, functional packaging machine, but the valuethat makes us competitive in the market.10

A New Logo all Around the WorldPFM Group The Packaging Experience: the new logo.The PFM Group serves the biggest names in the food andnon-food industries all around the world, with its flexiblepackaging technologies and with the continuity and extensivecoverage of its customer service.The new PFM logo springs from this and expresses the guidingvalues that inspire and unify all the companies in our Group.The sphere: symbol of the world in which we operate every day,representing the closeness and the interconnection betweencompany and customer.However the sphere also symbolises the product, the focusof our attention, the object for which we research and developtechnology, the millions of products that our machines packageevery day all around the planet: the product as the unifyingelement.The sphere also expresses strength, reliability, a landmark inthe packaging universe.The P, as in PFM, as in Packaging: a unique, original shape thatidentifies us, that wraps itself around the sphere, that protectsit just as the film protects the product, just as the atmosphereprotects the Earth.We decided to interpret the two forms with 3D technologyto communicate not only strength and intensity, but also toexpress a sense of innovation and contemporary significancethat counterpoints the position of “The Packaging Experience”– experience at its very best as a blend of know-how, history,memory, and power of observation.Andrea FioravantiR&D and Sales Director12

• A new item for the vertical world: PFM Supernova. • PFM Scirocco, a high performer. • New packs: the new PFM DuoBag®. • The world of Large Retail Organization,under constant analysis.PFM: a Constellation of InnovationsOur PFM Lab offers a journey into a world of innovation.A watchful eye on market trends and on the inclination to consume confirmour belief that packaging with plastic and flexible film will be fundamentalin the future of the packaging industry.Flow pack has become universally recognised and its use is becoming moreand more widespread due to the advantages it offers in terms of minimalenvironmental impact, reduced costs, and extreme versatility.This is why PFM is concentrating its efforts on two fronts:1. The development of applications for fast vertical packaging;2. The development of special applications for horizontal packaging.And new machines are introduced: PFM Supernova for high speed singledosepackaging (up to 250 packs per minute);PFM Zenith Duo Bag that can fill stand up pouches with an additional“pocket” to hold a dedicated accessory; PFM Zenith Brick Pack that canproduce box shaped bags with folded top seal, similar to the brick pack, butwith flow pack advantages; Solaris Smart3S Steelo produces 4-corner sealstand up bags at high speed.The horizontal news is the PFM Falcon, an application dedicated to multipacksof fragile products like tomatoes, previously packed in trays.Coffee capsules packaging lines, a continually expanding market for whichPFM is the benchmark, have been further researched and perfected.The already highly acclaimed PFM Scirocco for packaging cheese slices in anew resealable pack has been developed further.The wet wipes packaging range has been expanded and refined to offercomplete lines with feeding systems, die cutting and labeling systems,robotic lid application systems.PFM is also achieving success with its “green packaging” alternative, byoffering the customer a complete series of flow pack machines that usebiodegradable and compostable packaging materials; PFM is convinced ofthe fact that these materials are the future of the packaging industry.14

• Cheese Slices PackagingPackaging Line for Cheese Slicesin Resealable Packs.Product: cheese slices in piles.Packaging: 8 and 16-piece resealable flowrappack with adhesive label.Production rate: up to 200 packs/min.Advantages: PFM technology, alreadysuccessfully applied to Pocket Bag® packagingis featured in this application which produces210 pre-cut and labelled packs per minute.• Hermetic seals for MAP packaging takeadvantage of the Long Dwell sealing systemwith the drive gears contained in an oil bath(patented by PFM).• Hygiene: AISI 304 structure; all productcontact parts can be sanitised and are made ofmaterials which comply with FDA standards.• Cantilevered structure: the mechanicaland electronic components are housed at therear of the packaging machine in separate,protected environments. The front of themachine is therefore free of obstructionmaking it easier to clean and productionresidue does not come into contact with themechanical and electronic parts.Open & Reclose SystemPFM Scirocco BA Servo InoxMain Features: The PFM Scirocco is a servoassisted horizontal flowrapper, made entirely ofSTAINLESS STEEL, which produces hermeticallysealedpacks with three seals, suitable formodified atmosphere packaging, starting froma reel of heat-sealable wrapping material.The PFM Scirocco is connected to an ATLautomatic feed system which loads theproduct from the processing line accumulationbelt. The packaging machine is also equippedwith a double labelling machine.• Servo machine driven by in-line brushlessmotors.• Automatic reel splicer.• Double expanding reel shaft with brakecontrol, reel diameter 400 mm.• Rapid coupling system for intermediate beltbetween forming box and long dwell end sealunit.• Motorised heigh adjustment of the long dwellend seal unit.• 3 pairs of tiltable and adjustable fin sealwheels.• Pre-heating bars.• Infeed belt with interchangeable pushers.Labelling system: The system comprises of aprinting unit and double labelling machine whichaffixes the Open and Close label and tamperevident safety seal.Software: The PFM user-friendlyprogramming system uses a touch screenpanel to set all the machine’s functionsincluding up to 50 separate programmes.Format changeover takes place automaticallyand regulates the following:• pack length;• speed;• product phasing;• print centring.• printing position on printer.• any feeders and/or accessories.Special functions are also included such as“no product no bag” and automaticadjustment of the fin and end seal units.15

• PFM Scirocco for Cheese SnacksHigh-speed cheese snacks:PFM has designed and produced a line tofeed and wrap mini portions of Parmesancheese snacks for a well-known leading Italiancompany producing and marketing ParmigianoReggiano cheese.The PFM Scirocco horizontal packagingmachine has enabled PFM to admirably meetthe customer’s requirements, which wereessentially high production rates, hermetic sealsand wrapping in a protective atmosphere.200 hermetically-sealed, modified atmospherepacks (MAP) a minute..The PFM Scirocco has been equipped withthe Long Dwell HS sealing system featuringtwo up CRIMPERS and a high-speed IN-LINEfeeding system, which enables it to produce200 hermetically-sealed 40x20x20 mm packsa minute. The machine has been designed towrap portions of Parmesan cheese of varyingweights and shapes from a minimum of 20g. to a maximum of 125 g. and guaranteesresidual oxygen levels of lower than 0.3 %,thereby considerably prolonging the shelf-lifeof the product. PFM Scirocco featuring AML inlineautomatic feeding system.As well as offering unquestionable advantagesin terms of operating speed and reliability,the PFM Scirocco can be completely cleanedand disinfected: the structure is AISI 304stainless steel, with rounded corners, all theproduct contact parts can be sanitised and aremanufactured using methods and materials toFDA quality standards.The cantilevered structure enables themechanical and electronic components to behoused in separate, protected compartments,leaving the front of the machine completelyunobstructed and accessible.The packaging machine is completely servoassisted,all its functions can be programmedand it is equipped with an on-line servicingsystem for remote control of all the functions.The PFM Scirocco is equipped with the highspeedAML in-line automatic loading systemfeaturing three belts for accumulation, controland synchronisation of the product arriving onthe flow pack machine. The system can becompletely dismantled and thoroughly cleanedand disinfected.16

• Horizontal Wafer Feed and Packaging LinePFM has designed and manufactured anautomatic feeding and packaging line forwafers, with unique speed features and acompact footprint, for one of the leadingproducers in the Egyptian bakery andconfectionery industry.The customer’s requirements:1. to produce 250 packs per minute of singlewafers with product dimensions 84.2x37x17mm, the wafers must be packed short edgeleading;2. to produce 150 packs per minute of 4 waferswith total pack dimension of 96x67.6x17mm, the wafers must be packed long edgeleading.PFM proposes a feeding and packaging lineconsisting of:Feeding system: 2 automatic 110° CrossFeeder systems positioned in front of eachother: both receiving wafers direct fromthe production line. The feeding systemsare powered by independent motors, PLC–controlled and are perfectly synchronized withthe machine’s packaging speed.2 carousel feed systems positioned betweenthe infeed belt at 110° and the in-line feed beltused exclusively to obtain multiple packagingformats with 4 wafers and to group singlewafers from the long edge as they arrive forpackaging.Packaging: 2 horizontal packaging machinesmod. PFM Falcon Servo, fully electronic, forhigh-speed production of bags sealed on threesides.17

PFM Falcon ServoPFM Falcon is a horizontal flow wrapper ableto produce bags sealed on three sides from aroll of heat sealable material. Easy to clean:PFM Falcon has cantilevered construction.The mechanical and electronic components arehoused at the back of the packaging machinein separate, protected cabinets. The front ofthe machine is clear to facilitate cleaning of allproduct contact parts.Versatility: PFM Falcon is particularly flexible;it can pack a large range of products withfast change over times, and is available in 9versions to satisfy all product and productionrequirements.18

• PFM Bora Line at 110° for WafersPFM Bora is a horizontal flow pack typepackaging machine for producing packssealed on three sides from a roll of heatsealablepackaging film.• Speed and versatility: PFM Bora reachespackaging speeds of 200 ppm withmaximum flexibility.• Pack length: min. 40 mm max. 300 mm.• Pack width: min. 5 mm max. 220 mm.• Product height: max. 100 mm.• Changeover: The sealing speed and packdimensions can be changed in just a fewminutes.Technical Features• Infeed conveyor 2 m long withinterchangeable product pushers. Thestandard machine is supplied as a right handversion, with product flow from left to right.• Adjustable forming box for products ofvarying sizes.• Longitudinal sealing unit consists of 3 pairsof wheels. The first pair pulls the film, thesecond pair seals, the third pair maintainstension on the film and folds the fin seal.• Transverse sealing unit consists of 2“cut-seal” type crimpers with separatetemperature control.• Self-centring reel holder shaft withmicro adjustment of reel centring andcompensating brake.• Max roll width 500 mm, max diameter 350mm.• AC motor drive with electronically controlledstart and stop.• Product contact parts made from AISI 304stainless steel.• Painted steel frame.• Product discharge conveyor made from foodgrade material with independent motordrive.• Castors with stainless steel support forrepositioning the machine.• Seamless integration: the packagingmachine can be combined with a completeseries of automatic feeding systems forbakery and confectionery products.19

• PFM Ghibli: Packaging of bakery productsThe PFM Ghibli horizontal packaging machine produces packs sealedon three sides from a roll of heat-sealable packaging film. The machinefunctions are PLC-controlled with colour Touch Screen Interface.Products: Christmas and Easter bakery products such as Panettone, Pandoro,Colomba, etc.Product weight: 500 g, 750 g, 1000 g.Packaging: pillow pack type packs or packs with open sides for closure withclipping machine, from a roll of flexible film.Production rate: 50/55 p.p.m. with pack lengths of 500 mm.Advantages: normally in this market CAST polypropylene bags with an openend are used for primary packaging, PFM Ghibli uses the same material,supplied in rolls, and forms the bag with the product inside. This results inhuge advantages on the final cost of the individual pack, excellent packpresentation, with a packaging speed that reaches 50/55 products/min.Technical features:Longitudinal sealing unit consisting of three sets oftemperature controlled wheels configured to producelongitudinal bead seals, complete with motorised trimremoval system.Power-assisted Box Motion type transverse sealingsystem driven by two independent brushless motorswith automatic adjustment of:a) Crimper dwell time and height;b) Wrapping speed;c) Sealing pressure;d) Special sealing jaws for CAST PP film.Automatic crimper opening system in the event ofcontact with product.Optional:• Double reel holder shaft with automatic reel splice.• ATL Automatic Feeder.Flexibility: Option of fixed bag length or LVA mode(automatic adjustment of the pack length according tothe variable length of the product). The operator canset the required additional tolerance and gap betweenproducts.Sanitisation: Stainless steel cantilevered structure.All product contact parts are made of completelysanitisable stainless steel or polyethylene.20

• PFM Pearl• PFM PearlPFM Pearl is the full servo horizontal pillowpackwrapper to obtain pillow-pack style packsfrom a flat reel of heat/cold sealable wrappingmaterial. Sturdy construction with a carbonsteel fabricated frame, compact design, cuttingedge hardware, reliable and operator friendlycontrol software are the results achieved inthis project, expression of experience achievedin many years of manufacturing of flowpackmachines and automated lines.A high quality innovative machine.Operation: full servo wrapper with axis motioncontroller and brushless servomotors.To drive: infeed conveyor, fin seal rollers,sealing crimpers.Human/machine Interface: colour touchscreen. User friendly HMI to adjust all themachine parameters and save them ina dedicated recipe. The PFM Pearl willautomatically adjust the bag length, printregistration position, the crimpers position thedwell and the wrapping speed.The adjustment of the sealing temperature ofthe fin seal rollers and the transverse sealingcrimpers is integrated into the touch screen.No mechanical drives: drive motors areconnected directly to the various assemblies.The electrical panel is housed inside themachine frame and protected from the externalenvironment.Cantilevered Construction: manufacturedwith modular pre-assembled units designed tobe easily accessible and replaced.The front of the machine is free from anyobstruction. Elegant and rational design, simpleyet sturdy construction.Compact design, easy cleaning: thanks tothe cantilevered construction and the use ofpolymer moulded components with gracefulradiuses there are no dust traps.All guards can be easily removed.Ergonomic design: HMI and start/stop buttonshave been ergonomically situated to facilitateaccessibility.High speed and versatility: up-to 120 cycles/min. and capable of wrapping endless differentproducts in the food and non-food sectors.• PFM Pearl Stainless Steel22

• Packaging Line For Coffee CapsulesProducts: rigid coffee capsules wrapped individually or in pairs.Packaging system: flowrap, hermetically sealed using Polyester/aluminium/ Polyethylenebonded film, maximum caliper 70 micron, gas flushed.Production rate: 270/280 products a minute for individual capsules - 135/140 products aminute for double capsules.Advantages:• A single line is able to wrap 100% of the production of most modern rigid capsuleassembly lines.• Completely hermetic packs at a speed of 270 packs/min.• Less than 0.5% residual oxygen.• Substantial savings on film as this is wrapped directly around the product.• No machine downtime for reel changing.• Format change from 1 to 2 capsules in just a few minutes.• Automatic Tray Loader + PFM Mistral23Line arrangementAutomatic carousel loader, Falcon or Mistralhorizontal packaging machine, rotary printer.Description of LineCapsules coming in from the filling andassembly line arrive onto a flex link type beltand are then loaded onto an accumulationbelt. The line is controlled by photocells, anddepends on the amount of product present inthe storage unit.The machine-feeding carousel picks up acapsule from the incoming line and positionsit directly in front of the machine loading beltpusher. The capsule is wrapped in pillow packwith lengthways and crossways seals, theflowrapped packs are counted and conveyedtowards manual or automatic cartoning lines.Special features of the line• Long dwell sealing system (PFM patented)high speed up to 4 jaws per shaft: guaranteesperfectly hermetic seals as sealing time isprolonged, and can produce up to 400 packs aminute.• Total hygiene and accessibility on all sides:the machine has a cantilevered structure withrounded corners made entirely of AISI 304; themechanical and electronic components arehoused at the back of the packaging machinein separate, protected environments, so thefront remains free of obstruction and thereforeallows all parts of the machine to be easilycleaned, an essential feature for packaging inmodified atmosphere (M.A.P.)Versions available:• Mod. Falcon painted and stainless steelversions (up to 200 packs/min).• Mistral, stainless steel version (up to 300packs/m).• Servo (4 axis) version, colour touch screen.• Automatic reel change.• Remote on-line assistance.• Production counter.• Long Dwell High Speed version with 2, 3 or 4jaws per shaft.• Automatic Tray Loader + PFM Falcon

• PFM Blizzard Hard Candies 2000PFM Blizzard Hard Candies 2000: flowrap typehorizontal packaging machine producing up to 2000packs a minute of hard candies starting from a reel ofheat or cold seal wrapping material.The machine is completely servo-assisted, is drivenby direct in-line electric brushless motors, has acantilevered structure and is equipped with automaticreel changeover.This packaging machine is fitted with a special heatedautomatic disc loader with counter-rotating plate,controlled by an independent motor, which enables itto be synchronised with the packaging machine takinginto account the size of the product and acceleration anddeceleration ramps, therefore optimising productionlevels.• PFM Blizzard HS Cut and flowrap bubble gum.• PFM Blizzard Hard Candies 2000.24

• PFM Falcon Servo for Tomatoes PackagingTomatoes packed in Pillow Packs on PFMFalcon Servo using Horizontal FlowrapSystem.Products: tomatoes and other round fruitsand vegetables usually packed on trays (eg.:apples, kiwis, onions, peaches, etc..)Type of packaging:• conventional pillow pack containing 1, 2, 3products.• conventional pillow pack containing 4 (2+2)products.• conventional pillow pack containing 6 (3+3)products.Production rate:• up to 80 pillow-packs containing 2 productsa minute.• up to 70 pillow-packs containing 3 and 4products a minute• up to 60 pillow-packs containing 6 productsa minute.Advantages: Falcon Servo features versatileformat change and can produce packscontaining 1 to 6 products depending onrequirements.Eco-Savings: produce previously packedin trays or on tray + pillow bag can now bepacked in pillow packs only, providing obviousadvantages in terms of packaging costs andsimplified waste disposal.Innovation: the infeed conveyor, which carriesthe product, and forming tunnel, designedspecifically for this application, are designfeatures that enable a horizontal machineto pack pillow pack products traditionallypackaged on vertical packaging machines. Thisprevents delicate products from becomingbruised or damaged.Horizontal Flowrapper PFM Falcon Servo:Horizontal packaging machine producingpillow-pack type bags from a reel of heat orcold sealable paper or plastic wrapping material.Steel monoblock frame structure painted withthree layers of scratchproof epoxy paint ormade of stainless steel. All product contactparts are constructed from 18/10 stainlesssteel.Features:• A double chain infeed conveyor belt isfitted with product carriers and pushers withcounter-pitch, which can be adjusted bymeans of a handwheel to suit the grade ofproduce.• Vertical guides with idle rollers gently moveround, fragile products forward.• The forming box is adjustable to suitdifferent-sized products.• Small rotating belt fitted at the bottom ofthe forming box helps insert the product intothe wrapping material.• Brush conveyor mounted above the fin sealdeck plates gently maintains product positioninto the film and through the end seal jaws.• Three pairs of separate, tiltable fin sealrollers for the longitudinal seal; the third setalso folds the film.• Pneumatically opening fin seal wheels• Rotary crimpers for crossways sealingmaximum diameter 200 mm, with separatetemperature control.• Self-centring reel-holder shaft with precisecentring adjustment. Brake equalizing systemto maintain consistent braking intensity.• Driven by 5 DC in-line electric motors.All machine functions are set and controlledthrough a touch-screen control panel.25

• PFM Scirocco Wipes LinePFM Scirocco Wipes Line: a top of the rangePFM horizontal packaging machine, alreadypopular due to its extremely high performance,has been further developed. The Long Dwellsealing system featuring oil-bath transmissionenables this packaging machine to produceup to 200 hermetic packs a minute. It is idealfor wrapping tissues and wet wipes, whichrequire hermetic seals to maintain consistenthumidity levels, prevent leakage and preservefragrance.Interpack will be the venue for the presentationof the PFM Scirocco featuring a high-speedin-line feeder which conveys products fromthe processing line directly onto the wrappingmaterial, an electronic die cut unit for precuttingthe wrapping material to produce thepack opening and a labelling machine to applythe adhesive re-seal strip (to re-close the packonce the product has been opened).The PFM Scirocco can be thoroughly cleanedand disinfected: it is constructed from AISI 304steel with rounded corners, all the productcontact parts can be disinfected and are madefrom FDA compliant materials.The cantilevered structure enables themechanical and electronic components to behoused at the back of the machine in separate,protected cabinets leaving the front freefrom obstruction and therefore easy to clean.The automatic in-line feeder is made up ofindependent belts which space out the productand synchronize its arrival in the flow pack line.It features a cantilevered structure, and can becompletely dismantled and sanitised.• PFM Scirocco Line• PFM Shamal Line27

• PFM SupernovaSupernova: the project.The concept was to design a high-speedweighing and packaging line in the mostmeticulous detail specifically for the singleportionpackaging sector, suitable for snacks,crisps, confectionery and similar productsweighing approximately 10 to 100 g.In short, a line that would deliver outstandingperformance in terms of speed and averageproduction rates and at the same time besimple to programme and able produce highlyeffective, quality seals with extremely preciseweights.The result was the development of the PFMSupernova, a packaging machine designed toproduce up to 300 sealed packs a minute withthree perfect hermetic seals.The 16-head Series C3 weigher offers a nominalspeed of 280 weighings/minute.The PFM Supernova combination produces upto 250 finished packs a minute.The PFM Supernova is an extremely compact,robust machine dedicated to the single portionindustry that uses highly developed electronicsand simple, effective software.•Operation: Full Servo Controlled, completelyautomatic.• Sealing system: Long Dwell.• Film feeding: CBA automatic reel changeover.The line is equipped with a single touch screenpanel for programming and controlling boththe weigher and packaging machine, withguided programming logic.The state-of-the-art software is equippedwith numerous functions for self-regulatingparameters (phasing product drop, sealingtimes, temperature).The line allows the VFFS+multi-head weigher tobe connected to wireless LAN for downloading/uploading data, programmes, statistics andoutside connection for remote servicing ifnecessary.Some of the Features:1. Cantilevered structure to allow easy access to internal components, film feedarea and also allow for easy cleaning and disinfection.2. Internal expanding reel shaft with automatic reel splice.3. Long Dwell, High Speed sealing system featuring 2 or 3 crimpers per shaft oralternatively a rotary sealing system with 2 or 3 crimpers.4. Hardware with high data processing capacity and transmission speeds.5. Programmable and independently adjustable sealing times that can be savedinindividual product programs; these can be increased or decreased and remainconstant even when packaging speed is increased (within the limits of theproject).6. Automatically regulated synchronisation between weigher and packagingmachine irrespective of speed. This means that when the packaging speed ismodified, there is no need for the operator to intervene to regulate rephasing.7. Single touch screen for programming the packaging machine and weigher.8. “No product, no bag” function.9. Fully Servo-Assisted.31

PFM Supernova32

• PFM Solaris Smart 3SThe new PFM Solaris Smart 3S is a continuousmotion vertical form-fill-seal packagingmachine designed and manufactured by PFM,for high speed production of pillow bags,traditional 3-seal block bottom bags and4-seal stand up bags (Steelo Bag).With the Smart 3S sealing system, patentedby PFM, the machine reaches speeds of up to200 pillow packs per minute, 90 Steelo Bagsper minute and over 100 block bottom bags.PFM Solaris has been developed followinganalysis of market trends, reflected in particularin large scale retail, that is increasingly lookingto replace rigid packaging with flexible standup bags: lower environmental impact, smallerfootprint and lighter, without affectingthe benefits of aesthetics, customisationand marketing. The PFM Research andDevelopment Dept. has designed a machinethat not only guarantees top quality from adesign and marketing viewpoint, but at thesame time reaches unprecedented speedsnever before seen in the packaging industry.Main Features:1. Exclusive Smart3S sealing system withcontinuous box motion. The vertical motionand horizontal sealing axes are individuallyprogrammable and totally independent.The sealing unit consists of a patented motionsystem which has enabled the overall weightto be reduced considerably thereby improvingperformance and reducing mechanical stresson the components.2. The advanced Axis control softwareallows independent control of the sealingtime and production speed. This function isparticularly useful during start up and alsoensures constant temperature of the sealingjaws. Consequently, as the sealing time isconstant throughout the varying productionspeeds, operator intervention is not required.To complete set up the operator is simplyrequired to enter the pack length, sealingtemperatures, production speed.3. Steelo system in calender (4-side sealsquare stand up base): consists of a formingand sealing unit positioned within the film feedinstead of on the forming tube. Consequently,the overall height of Steelo-Bag version isreduced.4. Gusset tucking and folding device: thanksto the particularly long vertical stroke of theSmart3S and its light weight it is possibleto guarantee optimum sealing time whilstsynchronising the movement of the gussettucking fingers (Servo) and folding device(Pneumatic) without loss of productivity.5. Automatic reel splice: simple, compact,extremely efficient ensuring the reel changeis totally controlled by software that will, onrequest, shut off the product infeed and rejectthe pack with the splice.33

• PFM Zenith DuoBag ®PFM Zenith DuoBag® (PFM patent): a newVFFS vertical packaging machine whichproduces packs with a pocket for puttingin gadgets or accessories needed to use orconsume the product. Patented by PFM, themachine in this exclusive configuration forthe production of DuoBag® packs producestwo packs in one, starting from a single reelof packaging material and a single formingtube, which has been specially designed forthis application. Ideal for wrapping a productand an accessory: for example fruit andvegetables in chunks, cheese and processedmeat and salami cubes wrapped with theirown cutlery and wipes; candies, toffees,sweets and confectionery products in generalwrapped with gadgets and toys for youngconsumers; mixed frozen foods, fresh or driedpasta wrapped with a sachet of spices orflavouring that provides the correct amount ofseasoning, or to try out new, risk-free recipes,etc… In other words, a pack that broadensthe confines of everyday usage and radicallychanges consumer habits.34

• PFM Zenith BrickPFM Zenith Brick: VFFS type vertical packagingmachine producing stand-up packs with asquare top and base (Brick Pack).PFM Zenith Brick configuration is equippedwith a rotating carousel system divided intosections, that accept the packs once theirsquare bases have been formed and they havebeen filled. It folds over the top of the packand applies the label.The system is made up of a series ofindependently motorised modules, which aresynchronised perfectly with the intermittentmotionpackaging machine. The carousel isfitted with a vibrator that settles the productinside the pack, while a second device regulatesthe height of the packs and releases excess airbefore proceeding to seal and folding over thetop and finally applying the label.The machine is constructed entirely of anticorodalaluminium and steel with an hermeticbox structure, which guarantees that themechanical and electronic components areprotected from the external environment.The PFM Zenith is particularly flexible, withformat changeovers taking only a few minutes,enabling different pack styles to be produced:from conventional pillow bags to stand-uppacks with 4 seals and a square base and thebrand-new brick pack.The brick pack combines all the advantagesof rigid packaging with the characteristicshape, whilst still being produced from flexiblematerial.35

• PFM AF-5000 Auger FillerPFM AF 5000 is a modern, state-of-the-artvolumetric dosing system used for a widerange of powder products.Volumetric Dosing: the volume of product tobe packed is determined by means of a screwsystem, which rotates to provide a presetquantity. The amount of product portionedis determined by the pitch and dimension ofthe screw.Precision and consistency: The meticulousdesign and construction of the PFM AF 5000auger, the perfect finish of the product contactsurfaces, the precision and consistency onthe angles at which the screw moves and theway it rotates, guarantee the PFM AF 5000maximum dosing precision.All the component parts have been designedand constructed with the utmost attention todetail in order to convey a regular volume ofproduct.Products: sugar, salt, powdered drink mixes,cocoa, coffee, flours etc.Advantages: The PFM AF 5000 is controlledby a PLC which simplifies the machinecontrol functions: auger rotation speed canbe controlled and altered at any time, evenduring operation, to suit changing ambientconditions and the different types of productsto be portioned. All regulating parameterscan be memorised and easily recalled by theoperator.Main Features:• Machine controlled by PLC.• Operation controlled by 1 motor for theagitator, 1 (optional) for the feeding systemwhich accepts the product and controls theamount discharged into the dosing cone,1 brushless motor for driving the dosingscrew.• Construction: All the product contact partsare constructed from stainless steel andanti-corodal aluminium suitable for use withfoodstuffs.• System for checking product level insidethe dosing cone.• A range of different accessories suppliedaccording to product: the auger can befitted with a range of different terminalsand devices, which regulate the productdischarge in different ways.• Example of VFFS Machinewith PFM AF 5000 Auger Filler.PFM AF-5000: for a wide range of powder productsApplications• VFFS type Vertical Machines.• Thermo-forming Machines.• Doy-Pack Machines.• Poucher Machines.36

• Cow and Buffalo Milk PackagingProducts: Cow and buffalo milk used in themanufacture of mozzarella.Packaging:• 3-seal pillow bag up to 6 litres on ZENITH.• 3-seal pillow bag up to 12 litres on PV 320.Production rate:• ZENITH EW - Up to 12 five-litre packs/min.depending on type of packaging materialused.• PV 320 - Up to 8 ten-litre packs/min.depending on type of packaging materialused.Packaging material:Special PA/15 and PE/100 bonded material,for use at low temperatures (freezable).Line comprises:• PFM ZENITH INOX EW or alternatively, modelPFM PV 320 packaging machine.• Special dosing device for milk.• UV ray unit for sterilising film.• Vacuum pump for removing excess air frominside packs.• Mobile bag support system.• STAINLESS STEEL discharge belt.Advantages:• Fully automatic system directly connected tothe milk processing line.• Improved pack hygiene compared totraditional packaging in cans.• Finished packs are more compact and easierto store than traditional cans.• Laminate wrapping materials enables fastfreezing and defrosting.PFM Zenith INOX EWForm-fill-seal type packaging machinewhich produces 3-seal hermetic packsstarting from a reel of heat-sealablewrapping material.• Max film width 700 mm.• Machine constructed in 304 stainlesssteel.• All product contact parts constructedfrom AISI 316.• Electronic temperature control with+/- 2 °C accuracy.• All functions controlled by PLC usinga programmable keyboard.• Forming tube with rapid couplingsystem for extremely quick formatchangeovers.PFM PV 320 PN INOXDOSING DEVICE: The special PFM milk dosing deviceis also suitable for dosing concentrated milk; it isconstructed entirely of AISI 316 steel and comescomplete with 30-litre accumulation tank, specialfoam-prevention injectors and is also designed tobe coupled with a centralised CIP washing system.Form-fill-seal type packaging machinewhich produces pillow packs with 3seals from a flat reel of foil wrappingmaterial.• Max. wrapping size 800 mm.• Single block structure made entirely ofAISI 304 steel.• Comes complete with the samefeatures and accessories as the ZENITHINOX EW with the capacity for largerpack sizes.37

PFM: inimitable.MBP Series C4 with memory bucketsLinear combination weigher designed for high speed andextremely precise weighing of particularly delicate andfragile products. The operating principle is based on thedistribution of product in 6/8 weigh pans and 6/8 memorybuckets and on the identification of the best dischargecombination.• Weighing accuracy: 0.1 – 1.5 g (depending on producttype).• Nominal speed: up to 80 weighings/min. (dependingon product type and target weight).• Protection rating IP66: can be washed with directwater jets.• Operation: stepper motor.• Exclusive, highly advanced, easy to programMBP software.• 100% Made in Italy.PFM Automatic feeding and weighingsystem for mozzarella balls, braids andknots.PFM Automaticmozzarella feederReceives product fromthe hardening vat.Consisting of a stainlesssteel product collectionvat with radial internalcorners and a loadingconveyor for feeding thecompletely sanitisableweigher, equippedwith internal washingsystem and fittingsfor connection to thecentralized CIP system.The Zenith Inox SuperclipVertical packaging machine designed specificallyfor the dairy industry, produces packs with clipsfrom a roll of heat sealable wrapping material.All stainless steel construction, protectedagainst debris, designed to work inextremely aggressive environments,capable of up to 50 packs withclip per minute.MBP Multiple tray shuttlesystem.Shuttle system for automatic andsynchronised feed to tray sealer. Mountedon wheels for easy removal and cleaning.Not used when the weigher feeds the bagmaker.PFM Automatic Clipping MachineAutomatic high speed clipping machine: installedbeneath the bag maker, completely protected againstdebris.PFM S.p.A.PACKAGING MACHINERYVia Pasubio, 4936036 TORREBELVICINO (VI) ITALYTel: (+39) 0445. 66.22.00Fax: (+39) 0445. 57.01.75www.pfm.itpfm@pfm.it

• New Ultrasonic Sealing Packs. • The new vertical BG Vetta. • The new horizontal BG 4800.BG Pack: the Frontier of TechnologyBG Pack is an international market leader in the production ofmachinery for vertical and horizontal resealable packaging.The company produces special machines such as: the new BG4800, a technical development of the already popular BG 2800.A horizontal packaging machine that produces three-seal packsthat are resealable with zip or adhesive tape.The new BG Vetta, vertical packaging machine known for itsversatility and ability to produce marketing oriented packs (themachine can produce over 30 different types of pack) and ispresented at Interpack with the new ultrasonic sealing system.40

• BGPACK Vetta Ultrasonic Sealing SystemBG Pack VETTA Ultrasonic Sealing: verticalpackaging machine with new ultrasonic sealingsystem. The BG PACK top of the range verticalmachine, already popular due to its extremelyhigh performance, is able to produce a vastrange of different, innovative packs withextremely quick format changeover times.With the ultrasonic sealing system, highfrequency electrical current is converted intohigh frequency mechanical movement.This generates friction, and consequently heat,only at the points where it is required.The heat generated is sufficient to melt mostplastics as well as other materials but isconcentrated on the points where it is requiredoffering an excellent degree of protection fortemperature-sensitive foods: grated and cubedcheese and cheese matchsticks, fresh saladsand fresh-cut produce, flours etc..The VETTA Ultrasonic is equipped with two inlinemotors controlled by A Siemens PLC withcolour touch screen. The packaging machineis totally accessible and can be completelysanitised.• Ultrasonic Sealing System: suitable for fresh food.41

• Horizontal Flowrapper BG 4800• Packages with ZIP.• “Open & Reclose” packagesMarketing Oriented: The BG 4800 producesflow pack packages with three seals that havea perfect appearance. Designed for High Speedpackaging, in MAP as well, with completelyair tight seals, compact, smooth, wrinkle freepackages and of the highest quality, for whenthe package appearance is of the utmostimportance.Cleaning: In just a few minutes the machinecan be completely cleaned, even in the mostdifficult areas, all of which are within reach,easily accessible and extractable. All parts incontact with the product are made of AISI 304stainless steel.Multijaw Crossways Prolonged Sealing Unit:Low pressure on product bars, low temperatureand a prolonged sealing time are thedistinguishing factors of the exclusive BG Packmultijaw system. The material remains tight,stretched between the jaws thus making itimpossible for wrinkles and defects to form.Each jaw has a separate temperature controlmonitored via the machine touch screen.If the temperature of any of the jaws fluctuatesout of the selected range the machine stopsautomatically with said jaw in a quick removalposition.The “Open & Reclose” Packages: Packagingwith a resealable tab and with an adhesivestrip or zip. “Open & Reclose” is a system thatallows the packaging to be resealed.It is suitable for all types of food products thatwould normally be consumed in two or threestages. The resealability of the packagingguarantees freshness and good preservationof the product, and its easy opening ensuresnotable marketing advantages for theconsumer.Control and High Performance: Up to 160packages a minute thanks to the rotatingmultijaw crossways sealing system with aprolonged sealing time (up to 22 jaws) and withejecting knife, and thanks to the longitudinallinear shoe sealing assembly which providessmooth and resistant seals. State of the artelectronics for the accurate control of centredwrapping material printing with regards to theproduct.User Friendly: Machine controlled by PLC withcolour screen touch panel.Additional Information:• Attractive, wrinkles and defects free packages.• Ergonomical.• Ecological.• Printable on both sides.42

• Increasingly faster and more reliable weighers. • New DMA function. • Remote control and diagnosis from mobile phone and tablet pc.MBP: Speed, Precision, RangeWe closed Interpack 2008 with the confirmed success ofthe Series C2 and C3 multihead weighers with memorybuckets and the presentation of the, then recently created,Series C1 Entry Level weigher. Interpack 2011 sees theconsolidation of the three series, the presentation of the,by now super proven, Series C4, the combination linearweigher for fragile products, the presentation of the DMA( Direct Memory Access) version for the Series C1, C2 andC4 weighers.“We did not stop for even a minute,” says AndreaFioravanti, MBP Managing Director. “We have continuedtirelessly along the road of development and innovation:4 Series of weighers have been the subject of ongoingtechnological improvement.The mechanical and hardware development of theproduct has advanced hand in hand with the software: ourweighers are controlled by software that is based entirelyon Windows CE, it includes advanced mathematicalfunctions, elimination of environmental disturbances andcontinual optimization of machine parameters.Our software has allowed us to push to the maximum interms of weighing speed and accuracy.The industrial PC adopted is capable of processing anenormous quantity of data in just a few milliseconds; theweigher can be perfectly controlled remotely even with amobile phone or tablet pc.”44

• MBP Software: the Key to Our SuccessMBP Software: the Key to Our Success.MBP was one of the first companies in the world toproduce multihead weigher management softwarethat runs entirely on Windows CE. The heart of thesoftware comprises a combinational calculationalgorithm and an equally sophisticated systemof analysis and annulment of environmentalinterference caused by the oscillation of thegantries. The software also contains a state-ofthe-artfiltering procedure called DSP (Digital SignalProcessing), which removes natural interferencewith the buckets, thereby speeding up weightstabilisation. MBP weighers use an industrial PCthat incorporates an extremely powerful newgenerationprocessor able to process an enormousamount of data in just a few milliseconds. Thecapacity of the processor and the hardware are anessential precondition for the use of the state-ofthe-art,high performance software. The softwarefeatures a series of automatic parameter adjustmentsystems that reduce the weigher programmingstages to a minimum (weight, limits, speed) therebyconsistently optimising the weigher function,contributing to the overall weighing accuracy.With free flowing products, the MBP Series C2 14-head weigher can discharge up to 200 weighingsa minute with maximum precision. This figure isa significant achievement and gives us an idea ofthe technology used and developed by our team ofextremely efficient technical engineers. Connectionto the ‘outside world’ is also possible: the industrialPC allows the weigher to be controlled remotely,enabling the on-line help system to be used forremote servicing and for upgrades or modificationsto be uploaded/downloaded. Alternatively,software can be upgraded via a USB port to whicha flash drive is connected for uploading from anordinary PC even via e-mail. The same key can alsobe used as a personal password.The software has a large number of functions:• Weight combination.• Combination and number.• Weight compensation by means of multipledischarges, ideal where heavy weights are involved,to achieve the greatest precision.• Dual function to feed two packaging machineswith the same product but at different weights.• Discharge function for up to 4 independent pointsto feed the same product through multiple rephasers(2 to 20 trays), thermoforming or thermosealingmachines.• Mixture function based on weight or number from2 to 8 flavours.• Mixture function based on weight or numberfrom 2 to 8 flavours or more but divided over 2or more weighers and controlled by a single PCand software. The flexibility of MBP hardware andsoftware in fact allows the number of heads requiredto be concentrated on one weigher or divided overseveral, and all the heads to be controlled jointlyand share the product. This enables each weigherto be customised according to specific productrequirements.The graphic interface is extremely simple and easyto follow. Up to 1000 recipes can be stored in thememory. All the machine’s parameter optimisationdata is also linked with each recipe.The various automatic parameter optimisationfunctions take place in real time allowing theweigher to continuously adapt to the changingconditions of the product. These functions areextremely useful if we take into account the factthat foodstuffs are always sensitive to relative airhumidity, temperature and other natural variables.Modern software must feature state-of-theartcombinational calculations, environmentalinterference annulment and continuous automaticparameter optimisation. Modern, powerfulhardware is essential if we are to achieve all this.The result is weighing accuracy and eliminationof waste and unnecessary excess weights, whichadded up over time often constitute enormoushidden and avoidable costs.45• AVC SystemAutomatic VibrationControl• ARC System AutomaticRandom Control• ADC System AutomaticDrop Control• VIBCONTROL for thecontrol of vibrationamplitude• EVA System EnvironmentVibration Annulment• DSC System DropSequence Control• AMC System AdvancedMultihead Control• DSP System DigitalSignal Processing

• MBP: Quality in the Features• Touch Screen• Weight Control• Advance Industrial PC• NO Aluminium• Easy Accessibility• Self Diagnosis• Waterproof IP66• 100% Made in Italy• Product Mix• Counting• Memory Buckets• Internet Connection• Network• Data Acquisition• No Springs• MBP 24 C3 Series46

• MBP C1: Entry Level Top QualitySeries C1 Top Quality at Entry Level Cost.The new Series C1, launched in March 2009,has met with great success over the last fewmonths. Developed to offer an entry-level costalternativet, the new Series does not foregothe basic quality features typical of the C2, thenext Series up. The Series C1 uses the samehardware and software systems as the SeriesC2: 12.2” or 15” industrial PC and WindowsCE-based software. The Series C1 uses thesame powerful, precise vibrating bases as theSeries C2. The differences between the twoare basically the frame available in painted orstainless steel versions and the IP54 or IP65protection rating while all the Series C2 haveIP66 protection rating. The weighers do notuse return springs on the buckets as thesetypically represent bug traps. The bucketsare opened and closed by the same steppermotors featured on the Series C2. The Series C1is ideal for weighing dry granular products.The buckets feature a single-flap opening,which is ideal for dry products, (double flapopening is available on the Series C2 and isideal for wet or sticky products).The degree of accuracy is between 0.1 and1.2 g inclusive for up to 500 g and between1 and 2 g for final weights of up to 1000g. The buckets and vibrating channels areall made of 1.5 mm thick stainless steel toguarantee solidity and rigidity as well as animpeccable standard, and feature roundedcorners and smooth, limited welding seams.In conclusion, the Series C1 has a trulyoutstanding quality/price ratio. The fact thatit is made entirely in Italy must also be takeninto account. The Can-Open wiring systemguarantees that it is perfectly protectedagainst electro-magnetic interference.• MBP 10-C147• MBP 14-C1

• Cutting, Weighing and Packaging Linefor Grated/Shredded Cheese MixturesThe MBP Series 24C2 Twin Multi-headWeigher, is ideally suited for feeding Doypacktype horizontal packaging machines in thegrated and shredded cheese sectors, hasmet with widespread approval. The weigherfeatures a double discharge terminal, whichhas been designed to be coupled with theinfeed (generally double) of horizontal Doypackmachines.Three Basic Factors have led to the Weigher’sSuccess:• Precision: the average weight measuredby the type-approved weight controlsystem on 100 g products, working at 120discharges/min, is normally 100.2 g.This is a truly outstanding degree ofaccuracy.• Easy to clean: the 24C2 can be washeddown with water jets. The IP66 protectionrating guarantees it is totally waterproof.Moreover, the dehumidifier fitted insideprevents the formation of condensationwhen the outside temperature changes.The tubular frame has no hidden cornersand can be completely washed and allcomponents are completely rust proof.The weigher does not feature anyaluminium components.• Simple to operate: thanks to automaticparameter adjustment functions, all theoperator needs to do is enter weight, limitsand speed data.• MBP 24 C2 Series• Touch Screen• Mixing• DataAcquisition• EasyAccessibility• InternetConnection• Weight ControlMBP 14 C2 +PFM VFFS MachineMBP 24 C2 Twin +BG Pack Vettafor Doy Style PacksMBP 24 C2 Twin +PFM VFFS Machine Twin• Absolutely NOALUMINIUM• Network• Multi-pointDischarge• WaterproofIP66Protection• Self Diagnosis• CountingMBP 14 C2 +Heatsealing Packaging MachineMBP 24 C2 +Doy Pack Packaging Machine• CE Quality• AdvanceIndustrial PC.48

• 8-Flavour Mixture MBP 20C3 Mix LineMBP- a challengeIn the summer of 2009, a famous Europeanconfectionery company set a challenge forMBP Multihead Weighers which provided anextremely important and precious opportunityfor this Italian company to test the knowhow and technology it has managed toachieve through years of tireless research anddevelopment activities. MBP was to develop acounting and weighing line to count 8 differenttypes of chocolates and at the same timeguarantee weights that comply with Europeanregulations. The line had to offer flexibilityin terms of format as the customer requiredformats ranging from 220 g. to 5 kg inclusive.The 220 g. size was to be made up of a mixtureof 7 different types of chocolates. The averageweight of a chocolate is 10 g; the number ofchocolates in each flavour was to vary from aminimum of 2 to a maximum of 5 and withinthis range of possibilities the weight had tobe 220 g. +/-0.5 g. Production rate was to bearound 60 weighings a minute.The SolutionMBP produced a line composed of twoSeries 20C3 20 head multihead weigherswith memory cells. The most importantproblem, i.e. combining the number of piecescorrectly and at the same time guaranteeingthe accuracy of average weights was solvedbrilliantly by using just one control softwaresystem for both weighers, in other wordsa single PC for both multihead weighers.The software was to control 40 weighingheads and their corresponding memories atthe same time, giving a total, including thepre-dosing buckets, of 120 modules with 8vibrating feeder channels and 8 elevator belts,each with their own vibrating hopper. As wellas the 220 g format size, the system countsand weighs 490 g (50 weighings a minute),2.5 kg (10 weighings a minute) and 5 kg (8weighings a minute) sizes. The level of producton the central cone is controlled by ultrasoundsensors.49

ConclusionsOur goal was centred perfectly. “The successof this project assigns MBP a major role onthe international multihead weigher market,”states Managing Director, Andrea Fioravanti.“Working together as a team, my researchers,designers and technicians have had a chance todemonstrate all their skills here. The relationswe developed with the Customer also playedan essential role and enabled us to tackle theproblem with a positive open mind and spiritof collaboration.”• Control Panel.The line is composed of:• N. 2 multihead weighers MBP mod. 20C3 with memory buckets.• N. 8 elevator belts complete with vibrating feeding hopper.• N. 8 product feeding channels between elevator and the center of the weigher.• N. 2 transport belts for discharged product complete with timing hopper.• N. 1 “Z” belt to collect and transport the product mix to the packaging machine.50

• MBP 5 Mix Line + Steelo Bag at High SpeedMIX OF 4-5 TYPES OF BISCUITS IN PERFECT STEELO PACKS, AT 80 P/MIN.A weighing and packaging line capable of producing STEELO BAGS (stand-up packs witha block bottom and rigidised corners) containing a mix of up to 5 different types ofbiscuits. This is one of the latest developments to emerge from the technical collaborationbetween MBP and PFM.Customer’s requirements:A famous biscuit factory asked the companies in the PFM group to supply a versatile linefor the production of:• 50/60 g packs with 3 seals containing a single flavour, 130 ppm.• 100/125 g packs containing a mix of 2 flavours in STEELO BAGS, 80 ppm.• 200/250/300 g packs containing a mix of 4 flavours, 60 ppm.Solution offered by MBP and PFM:An MBP Series C3 24-head multi-head weigher withmemory buckets, fed by 5 elevators and 5 independentvibrating belts, and a PFM PV320 LONG DWELL verticalpackaging machine, with STEELO-BAG sealing unit placedoutside the forming tube on the film unwind calendarassembly. The machine is capable of producing up to 80Steelo-Bags a minute and 130 standard 3-seal packs/minute. The weigher is equipped with an intelligentproduct distribution system made up of mobile partitionssupported by a circular structure: this system makes itpossible to divide the top feeding line into 1-2-4 and5 flavours in just a few minutes using all the heads allof the time. So in the case of the 2-flavour format, theweigher uses 12 heads per flavour along with theirrelative memories. If we have 4 flavours, it uses 6 headsper flavour with the corresponding memories.In order to eliminate the dust naturally generated bybiscuits, special sieves have been placed at strategicpoints along the feeder system and a built-in, centralisedextraction circuit eliminates unwanted dust.The operator panel is extremely simple and easy to use.A target weight with corresponding limits, which can alsobe represented as a percentage of the total, is allocatedfor each flavour. Each recipe memorises the configurationrequired along with all the data for regulating the vibratingfeeder channels. The PFM PV320 LD packaging machine iscapable of producing Steelo Bags, with 4 sealings and ablock bottom with re-inforced fins (corners): the 4 sealsare produced by the calendar assembly and this allowsthe packaging machine to be fitted with a forming tubewith a round (not rectangular) cross-section which offersconsiderable advantages in terms of productivity and adrastic reduction in machine downtime.The film is automatically centred. The integrated automaticreel change system helps to raise average productionrates to maximum levels. The PV320 LD is fitted with aLong Dwell, continuous motion sealing system: the rotarysystem allows sealing time to be increased therebyproducing strong, aesthetically perfect seals.The system as a whole is driven by Brushless motors.51

• Dried Mushroom Mix:Small Packs, Maximum PrecisionThe construction of this weighing andpackaging line for a dried mushroom mixwas the result of PFM and MBP combiningtheir technical expertise.This application is particularly note worthybecause of its performance levels and abilityto pack not only an extremely lightweightproduct such as dried mushrooms within aminimum weight range, but also as a mix.Customer’s requirements: To produce mixedproduct packs in formats ranging from 20 to80 g.Example: the 20 g pack had to contain twodifferent types of mushroom, weighing 5 and15 g respectively. The accuracy of the individualweights was crucial as one of the mushroomswas porcino, an expensive product.Solution offered by PFM and MBP: PFMexceeded the customer’s expectations byoffering a ZENITH vertical packaging machinecapable of producing not only standard pillowpacks with 3 seals, but also block bottom packswith 4 vertical seals, in other words, Steelo Bags.The packaging machine is completely servoassisted,controlled by Brushless motors, whichregulate the sealing crimpers and film drawdown system independently. The packagingspeed for the configuration proposed was upto 50 packs a minute. The PFM Zenith EW ismade entirely of stainless steel and can befully cleaned and disinfected. Its “HermeticBox” enclosed structure and the constructionmaterials used guarantee complete protectionof the mechanical and electronic componentsfrom the external working environment.MBP 10 C3/MIX2: MBP proposed the 10-headmultihead weigher with memory bucketsdivided into 2 sections for dosing, weighing andmixing 2 different types of dried mushrooms.Two connecting vibrating channels work“proportionately”, each feeding half of theweigher, which means they can increase orreduce the amount of product dischargedonto the weigher so that the level on thecentral distribution plate remains constant.Radial channels, specifically designed for thisapplication ensure the product advances veryslowly from the central plate to supply theweighing buckets with a minimum quantityof mushrooms. Exclusive MBP software uses aspecial algorithm to carry out a further check.This calculates the individual weights neededto reach the target weight with the utmostaccuracy. The software makes it extremely easyto create new recipe mixes by simply enteringthe target weight in grams or as a percentageof the total along with relative weight limits.The weigher will automatically make all theadjustments necessary and constantly checksthese during operation.Extremely high Weighing Accuracy:The most outstanding feature of the 10C3/Mix2 is its weighing accuracy. By usingmemory buckets and a special combinatorialcalculation algorithm the weigher is able,in the case of a target of 20 g, to produce aweight of 20.06 g. In other words, there isan error over average weights of less than atenth of a gram. It is also worth mentioningthat the weigher is fanless, so it has no fansor cooling systems. Considering how dusty theworking environment is, avoiding the use of anair suction cooling system actually protects theweigher’s mechanical components, especiallythe internal parts of the hardware.52

• PFM Cocoa Powder Packaging LineCocoa Flow Pack and Box Packaging LineProduct: cocoa powder.Product weight: 200 to 600 grams.Type of packaging: block-bottom packs, maximumlength 400 mm and maximum width 300 mm(PFM Group) in cardboard box (CAMA Group).Production rate: up to 80 packs/min.Advantages:• Maximum flexibility: the line is designed toproduce a range of different formats and bedeveloped over time.• High productivity.• Packaging line is completely automatic from firstflow pack through to insertion into the cardboardbox.• Simple programming, control over all stages ofpackaging and maintenance.PFM Azimuth Servo:Vertical packaging machine for the production ofpillow packs and Steelo-Packs (rigidised cornersand block-bottom) starting from a reel of heatsealable film.Line composed of:• Vacuum conveyor.• Auger for powdered products.• PFM Azimuth Servo vertical packaging machine forthe production of block-bottom packs.• CAMA end of line with CL-155 sleever for insertingbag into box.Production CycleThe product is loaded into the auger by means of a specifically designedvacuum conveyor for powdered products. The high-speed, high-precisionauger has been constructed of AISI 304 and 316 L stainless steel withIP66 protection rating, specifically for cocoa powder. Once the product hasbeen packed in block-bottom Steelo Packs with rigidised corners on thePFM Azimuth Servo, it undergoes weight and metal detector checks.An automatic feeder system made up of an accelerator belt collects andloads the bags into the cells on the product conveyor of the sleever machine.A special device inserts the bags into the boxes which are then closedusing hot melt glue and conveyed towards the discharge conveyor.CAMA CL155 Sleever• Continuous or batch type sleever receives products coming from theprimary packaging line, phases them and inserts them in pre-gluedboxes.• Production rate: up to a maximum of 80 boxes a minute.• Main functions driven by independent brushless motors: chaintransporter for boxes, lever feeder, product insertion device, productconveyor with cells.• Ease of cleaning: painted welded tubular steel structure, houses theelectrical cables and pneumatic piping, which are easily accessedthrough inspection windows.• Accessibility and ergonomics: full-height transparent vertical guardsand construction based on the “easy entry” principle which enablesthe main functions of the machine to be accessed for maintenance orcleaning without interfering with the structure in any way.• Readily available hardware and software components (eg.: SiemensPLC, Indramat axis control, etc.) to ensure that the end customer caneasily manage and procure (both hardware and software) parts.53

• Pre-packed Crackers in MultipacksPackaging Line for pre-packed Crackers in Multipacks.The line comprises of product feed belts, multi-head weighers and vertical packaging machinery.Product: multipacks comprising of 26 small pre-packed crackers giving a total weight of 750 grams.Packaging: Steelo Pack, stand-up and block bottom bag.Production rate: the packaging line enables up to 60, 750 gram multipacks a minute to be produced.Advantages: the packaging line enables small, pre-packed crackers to be weighed accurately at highspeed and then wrapped in a robust, Steelo, stand-up pack with block bottom and 4 vertical side seals,ideal for marketing the product.Line Composition• Weigher feeding system comprising of beltconveyor feeding two elevated pivot stationspositioned on the gantry which sort the productand pass it on to the 3 weighers according torequirements. Two weighers are able to handle100% of production; in this case however,production is guaranteed even during reelchange-over (automatic) or if one of the threemachines stop.• 3 MBP Series 14C2 EEW multi-head weighers(bucket volume 9 litres) with 45° angles.• 3 Azimuth Steelo Bag Servo Form Fill Sealvertical packaging machines.Azimuth Steelo Bag ServoVertical Form-Fill-Seal wrapper for pillow andSteelo pack styles (4 sealed corners and blockbottom) starting from a flat reel of heatsealablewrapping material.MBP Multihead WeighersThe MBP 14C2 is a combination multi-head weigherconfigured as in dual-mode for this application.It functions as a weigher and piece counter.Features• Frame: tubular, easy to clean, made of StainlessSteel AISI 304.• Central vibrating cone with load cell dedicated toeven distribution of the product in the vibratingchannels.• Powerful cast iron vibrating bases.• Vibrating channels made of Stainless Steel AISI304 and shaped depending on the specificfeatures of the product.• Extractable, interchangeable segments.• Protective cover made of Stainless Steel AISI 304.• Pre-dosing pans and Weighing pans made ofStainless Steel AISI 304 with opening/closingcontrolled by step motors.• Industrial PC based on Windows with touchscreen which can be controlled remotely.Features of Hardware and SoftwareHighly developed and easy to program, featuring:• AVC System (Automatic Vibration Control).• ARC System (Automatic Random Control).• ADC System (Automatic Drop Control).• VIB Control (for the control of vibrationamplitude).• EVA (Environment Vibration Annulment).• The AVC, ARC, ADC, EVA and VIB Control worktogether simultaneously. These are particularlyhighly-developed software systems able tosimplify machine operations to the utmost andincrease efficiency and speed/accuracy levels tomaximum levels.• DSC (Drop Sequence Control).• AMC System (Advanced Multihead Control).54

• Direct Memory Access: MBP doubles therange of solutions available• Weigher Stainless Steel versionWith the introduction of the DMA (Direct MemoryAccess) function, MBP is set to become the companywith the widest range of weighers in the world.DMA is a system for managing the “memory bucket”function. With the DMA system, the weighing bucketdischarges directly into the memory bucket and fromthis directly onto the chutes. The use of memorybuckets exponentially increases the number of possiblecombinations. This means a huge increase in the speed/accuracy ratio. In other words, the DMA version is farmore accurate and much faster than the correspondingtwo-level standard version when working with thesame number of weighing buckets.Further advantages:• On the Series C2/DMA all the buckets can have asingle or double opening flap. DMA can therefore beused even with sticky, bulky or powdery products.• Drop is reduced and as a result so is the likelihood ofsemi-fragile or fragile products breaking.• The DMA version (for both C1 and C2) is available asTwin and Mix, just like the C3 version.• Weigher Teflon version• The icon identifying the DMA function.Some examples• Model 8C2/DMA: discharges up to 120 p/min.• Model 10C2/DMA: discharges up to 160 p/min.• Model 14C2/DMA: discharges up to 250 p/min.• Model 10C1/DMA: discharges up to 150 p/min.• Model 14C1/DMA: discharges up to 210 p/min.Pre-dosing bucketPre-dosing bucketWeighing bucketWeighing bucketMemory bucketMemory bucket55

• Multihead Weigher MBP 16C1 with System DMAMBP 16C1 DMA: multi-head entry-level weigher with the new DMA system applied; producesup to 260 weighings a minute.DMA Direct Memory Access System: DMA is a combinatorial calculation principle for thecontrol of memory buckets involved, along with the weighing buckets, in the identification ofthe best weight combination.• The memory buckets receive the weighed product directly from the weighing buckets.• The memory buckets are placed at the end of the chutes so they interrupt the fall andtherefore reduce the impact speed of the product.Advantages of DMA:• ‘When compared to the standard version, the number of possiblecombinations increases by about 600 times, raising weighing accuracyto the highest levels.• ‘Excellent also for semi-fragile products due to the positioning of thememory buckets at the end of the chutes, which slows down impactspeed considerably and therefore the likelihood of damaging fragileproducts.The Series C1 uses an advanced industrial PC featuring a particularlypowerful processor able to carry out complex mathematical calculationsin a very short time. The use of an industrial PC which features a powerfulnew-generation calculation processor has enabled highly-advancedweigher management software to be developed, which incorporatesstate-of-the-art algorithms and machine functions.The (embedded, fanless, diskless, wireless) PC used guarantees a highdegree of stability and durability over time. The high luminescence touchscreen panel is available as a 12.2” version.The Series C1 incorporates a state-of-the-art operating system. It featuresa Multi-Touch user interface, which enables any page to be accessedwith a maximum of two steps. The simplicity of programming is trulyamazing.By using the AVC, ADC, EVA and DSC functions, all the operator needsto do is simply programme the final weight, the upper and lower limitsand speed (wpm). All the information required to monitor the operatingstatus of the weigher in just a single glance is given on the Home Page.56

• MBP Series C4:new Multihead Weigher for fragile productsMBP Series C4: new multi-head linear weigherfor fragile, sticky and difficult-to-handleproducts.The Series C4, unlike conventional multi-headweighers, features parallel weighing channelsfed perfectly from two vibrating load plates.The combination of weights is made usingthe same criteria used for conventional multiheadweighers and in the DMA version, butthe absence of chutes avoids fragile productsbeing damaged. The Series C4 uses the sameI-PC and the same software suitably adaptedfrom the Series C1 and C2.Two extractable belts, which can be sanitised,collect the products dropping from theweighing channels and convey them tothe centre of the weigher, where a directconnection can be made to the forming tubeof a vertical packaging machine or a multipleshuttle mechanism feeding a thermoformingor thermosealing machine.Drop height is effectively reduced to a minimumand this ensures special treatment for delicateproducts.The weigher’s structure is made from AISI304 stainless steel, the mechanical finishesguarantee IP66 protection rating and thereforecan be washed down directly using pressurisedwater jets.The frame with rounded corners has no hiddenparts or points that are difficult to reach, thuspreventing the formation of bug traps.The Series C4 is available in the version withDirect Memory Access memory buckets, whichincrease weighing precision exponentiallyand enable the weigher to produce up to 70weighings a minute on the 8-head version.The Series C4 is available in a number ofdifferent versions: 4DMA - 5DMA - 6DMA -8DMA.57

• The new Direct Memory Access function.58

• Multi-head Counting WeighersMBP Multi-head Counting Weighers.MBP multi-head weighers are also availablewith count mode whenever a customerrequires a specific number of pieces to beinserted in a pack irrespective of the finalweight. The count mode software featuresslightly different programming stages fromthe target weight software in which, forexample, upper and lower weight limits andweighing speed are entered. In the countversion, the average weight of the individualcomponents is entered along with upper andlower limits; then the number of componentsto be discharged is entered.It is essential that the variation in weightbetween the individual components multipliedby the number of components to be dischargednever exceeds the weight of a singlecomponent, otherwise the weigher coulddischarge one more than the set number.To resolve this, if the speed in terms of packsper minute allows, multiple discharges can bemade to compensate for differences.For example, if a discharge of 10 bread rolls ofirregular weight is required, two discharges of 5bread cakes could be made in order to halve theeffect of the variation in weight. From the largeamount of experience we have gained in thebread, mozzarella cheese, mini salami, bakedgoods, frozen foods markets, etc…, the systemworks extremely well. In this case a rephaserbucket is needed for incorrect weighings,or alternatively it is worth considering thepossibility of using the packaging machine toproduce a two-part pack. The weigher mayget the number of components wrong duringstart up or in extremely rare cases duringproduction. The advantage of this weigher liesin the fact that it detects the counting error bytaking into account the weight of the individualcomponents and signals it by activating variousemergency options including the expulsionof the incorrect combination through theincorrect weight bucket. A multi-head countweigher is generally much more effective,simple and productive than a conventional inlinecomponent counter.• Example of Line for fruit andvegetables with Counting Weigher.59

• Pet Food PackagingWeighing and Packaging Line for Pet FoodProduct: dry and moist pet food.Bag style: resealable pillow-packs with zip and euroslot,doy-style and steelo-pack.Bag weights: 100 g. to 2000 g.Speed: • up-to 70 ppm with pillow-pack• up-to 40 ppm with steelo-pack• up to 50 ppm on Vetta doy-style packsWrapping material: heat sealable laminate PP/PEKey points: bag style flexibility, quick changeover, high production speed, easycleaning, perfect integration with weighing system.Line composition: vibratory feeding hopper, product elevator, cross feeder to theweigher (controlled by the weigher), multihead weigher MBP 10C2 Series (as analternative multihead weigher MBP 10C1 Series) gantry with ladder, VFFF baggerPFM Azimuth Servo. The line can also be supplied with VFFS BG Vetta verticalpackaging machine.MBP 10C2 Series10 head multihead weigher:• IP 66 protection grade.• Manufactured in Stainless SteelAISI 304.• Exceptional speed/accuracyratio.• Complete Line for pet food.The PFM Pet Food packaging line equipped with a VFFS BG PackVetta vertical packaging machine that produces doy-style standupresealable packs, in addition to the pack styles produced by thePFM Azimuth. These are ideal for a whole range of moist pet foods.The doy-style application produces a reclosable stand-up bag, witha reinforced gusseted base and a zipper to reclose the top of thepack.The packs can be gas flushed to produce aesthetically perfectmodified atmosphere packs (MAP) with hermetic seals.The doy-style pack is attractive, practical, economical and convenientto use: an excellent alternative to the traditional packaging in tins forthis type of product.60

• Mozzarella: at High Speed...And in TubsHighly-valued collaborationA joint project between MBP and MULTIVACto design a line for a well-known Italian freshcheese producer has recently been successfullycompleted. The line was for weighing andfilling tubs with mini mozzarella cheeses.Stainless Steel QualityThe line was constructed to take intoconsideration the conditions found in a dairyenvironment which are extremely aggressivedue to the presence of water and salt.Constructed entirely of stainless steel withrounded cornes and a finish that enablesthe line to be fully cleaned and disinfected.The system is free from any components ormaterials can can rust and/or corrode and canbe dismantled for wash down with with waterjets.High Production Rates, Maximum ReliabilityThe customer needed to achieve an averageproduction rate of eighty 125 g. tubs a minutewith automatic addition of brine to themozzarella packs. MBP solved the problemby developing a line comprising of a feedersystem specifically for mini mozzarella cheesesthat conveys the product from the productionline to the product collection tank, which isplaced above the gantry, and has a built-inC.I.P. washing system. After the product hasbeen weighed, the 14-head Series C2 weigherdischarges it into an in-line 8–tray rephasingbucket, which is also completely washable, justlike the completely washable tub denesterand conveyor belt. The 8-tray rephaser bucketperforms 10 cycles a minute and feeds theMultivac synchronisation belt, which carries theproduct to the T800 heat-sealing machine.61

• MBP Rephasing BucketsMBP Quality: The packaging speed isdetermined by the quality, efficiency andperfect integration between the weigherand the systems feeding and distributingthe product to the thermoforming andthermosealing machines. MBP offer a widerange of step single and multiple rephasingbuckets, which are totally customisable to suitall weighing and packaging requirements.MBP Rephasing Buckets: 2 to 12 tray rephasingbuckets available in hydraulic and 100% Servoversions. IP66 rating: can be completelywashed and disinfected. Typically used to feedthermoforming and thermosealing machines.The MBP range varies from 2 to 20 buckets.Can be driven by compressed air or step motor.IP54 protection rating (compressed air version)or IP66 (step version).If multiple rephasing buckets with 8 or moretrays are used, weighers often have to work indouble, triple or fourfold discharge function.In other words, with 2-3-4 exit cones.Example: If we feed an 18-tray thermoformingmachine that performs 10 cycles/min, for atotal of 180 discharges a minute, this cannotbe achieved with a single discharge.In this case we have to divide the weigherinto two sections with two discharge points,therefore 90+90 w.p.m. (speed limit) or threepoints 60+60+60.The number of heads needed to guaranteeproduction can be calculated from the numberof sections the weigher is divided into.In fact even though a 14C2 can discharge upto 180 w.p.m. (using suitable product), thiscannot be divided into two sections 7+7.A 7-head in fact would not guarantee eitherspeed or precision. A solution therefore couldbe a 14C3 (memory buckets) or a 20-headSeries C1 or C2 depending on type of product.• Two-tray rephasing bucket.• 6-tray rephasing bucket.• Various types of final packages.• Packaging trays.• Packaging Doy Style type packages.62

• MBP Series T2 Lidding MachineMBP T2 is a lidding machine for semi-rigidtrays generally used in the fruit and vegetablesector for tender and delicate produce.Packaging: 125 g., 250 g., 500 g., 750 g. and1000 g. PP, PET and PLA trays with lid.Produce: delicate vegetables and fruit suchas wild berries, cherry tomatoes, table grapes,apricots, peaches and cherries.Production: up to 40 cycles/min. for 2 traysper cycle. Total 80 trays/cycle.Advantages: the tray packaging of delicateproducts safeguards their wholeness andallows them to be stored in piles.General Characteristics: the completelyelectronic operation control allows themanaging of acceleration and decelerationslopes involving the lid conveying andpositioning system, according to the type oftray and the produce contained.The machine manages 2 trays per cycle.Packaging: PET polypropylene trays are the most widelyused containers in the fruit and vegetable sector, thanksto their multi-fold characteristics. Tough, transparent,hygienic and re-usable, the trays are not only suitablefor containing and preserving, but also for enhancing theproduce.250 gr. 500 gr. 1000 gr. 1000 gr.63

• MBP CLB 6000 Cup Fillingand Sealing MachinePacks with tray, film/foil lid and plastic lid.MBP CLB 6000 Cup Filling and Sealing machineThe CLB-6000 fills cups or trays of various shapes and sizes andhermetically seals them with a heat-sealed film/foil lid and and/or plastic lid. The machine can be combined with automaticfilling systems for use with granular products or liquids af varyingviscosity.Production rate: up to 120 packs a minute.Advantages: speed and hermetic sealing guaranteed.General Features: Complete electronic control of functionsenables each individual station to be controlled automaticallyand independently thereby guaranteeing maximum flexibility.• Examples of products.• Machine table, constructedfrom anodized aluminium.• Control Panel: Siemens PLC.• Detail of aluminium lid, heat-sealing station.64

• Case Study: AMAKHOSI CHICKENAmakhosi Chicken, a leading South Africancompany in the chicken meat industry,decided to take advantage of the PFMGroup’s know-how in order to create aweighing and packaging line for chickenportions. Let’s meet Richard Ford, PFMGroup agent for South Africa, who willoutline the commercial and technicaldetails of the project.•Who are Amakhosi Chicken?Amakhosi Chicken are one of the mainproducers of frozen chicken portions,supplying the market with 2 kg to 5 kg packsof chicken portions destined for the retaildiscount chains.• What are the characteristics and peculiarfeatures of this type of product?The chicken portions are deep frozen tominus 40°C, and so are extremely hard andslippery. Chicken is also highly irregular inshape and size and has a tendency to easilybecome wedged during the transfer processfrom the weigher to the packaging machine.• What were the Company’s productionrequirements?In just a few years Amakhosi Chicken haveattained a leading position in their relevantmarkets. In order to support growth, theCompany needed to increase its level ofautomation and as a result its productionrates. Automation means increasing notonly production speeds, but also safety andhygiene levels. In short: no hands touchingthe product and maximum productivity.• What did PFM offer?An MBP 14 C2 weigher specifically for frozenfoods, integrated with a PFM Zenith ExtraWide packaging machine.• Why were PFM chosen?Because for the food industry, and for thefrozen food sector in particular,PFM means “complete turn-key lines”from feeding to weighing and packaging,guaranteed accurate weights and completelyhermetic seals. Moreover, flow packpackaging in general brings down the costsof wrapping material significantly. BecausePFM has a great deal of experience with thistype of product, which is extremely difficultto work with. Because PFM was already verywidely known in South Africa in the “freshfood” sector, which requires machinery thatcan be sanitised to the highest hygienestandards. Because PFM has an independentorganisation in South Africa with a highlyefficient after-sales service, which isextremely important for the frozen foodindustry.• What advantages did these pointsrepresent for Amakhosi?For Amakhosi the advantages offered by thePFM industrial group greatly facilitated allthe business negotiations from enquiry rightthrough to design, planning and installation ofthe line. We also had the advantage of liaisingwith just one manufacturer, which will alsobe a benefit in the future when maintenancework is required. We have completelyeliminated product waste and returns due toopen packs, and have made life easier for thesupermarkets and consumers by supplyingthe product in flow pack packaging.1 Legs or drumsticks2 Thighs3 Wings4 Upper back5 Lower back6 BreastThe MBP + PFM SolutionMBP 14 C2 Multi-head Weigher, specifically for food:IP 66, Extra wide, producing up to 140 weighings a minutesubject to product type. Supplied in 60°-inclined ExtraWide version.PFM Zenith EEW: VFFS type packaging machine producingclassic 3-seal packs and 4-seal packs with block bottomstarting from flat foil heat sealable wrapping material.Supplied in stainless steel, which can be completelycleaned and sanitised; fully servo-assisted; able toproduce up to 140 packs/min subject to product type.66

• The new SPS premises. • SPS Regola. • SPS Modulo.SPS: New Premises, New ChallengesSPS Italiana Pack Systems, producing automatic packaging linesfor bakery products and biscuits, is preparing to open their newpremises in Bogogno (Novara).The premises, with an area of 6000 m² of production space and2000 m² of office space, is situated in a magnificent settingadjacent to the golf course. The factory’s modern spaciousfacilities house the structures and personnel of the companythat can boast the biggest sales increase for the two-year periodfrom 2008 to 2010.“A development trend that is also confirmed for 2011 and whichwe forecast will close with a turnover of 15 million Euros,” statesPaolo Fioravanti. ” Today SPS has a firmly consolidated positionwith the major producers of biscuits, wafers and bakery productsall around the world.”Business successes over the last two years, the result of untiringwork focussed on technological improvement and development,include the special applications for wafers and sticky products,which are particularly difficult to handle; the new slug portionerfor biscuits on edge; the new biscuit sandwiching machine; thenew biscuit stack forming and loading system; vibrating channeltechnology developed in collaboration with MBP and, last butnot least, the new SPS Regola packaging machine for candybars and bakery products that completes the medium speedrange and flanks the already popular high speed SPS Modulopackaging machine.68

• SPS-CAMA: Partnership and ReliabilityA consistent part of the CAMA philosophy inthe realization of highly efficient packaginglines, is partnership development with the EndUser.This line recently installed in Poland, representsone of the best examples of this partnershipdevelopment.It is in fact the fourth time that the customerhas requested such a challenging applicationfrom CAMA. Previously, CAMA successfullyinstalled packaging solutions in the company’sother European production facilities.This is indeed a turn-key project realized byCama together with SPS (PFM Group): such apackaging line is dedicated to pack cakes thathave quite a peculiar shape, at up to 45.000cakes per hour.After the cakes are flowrapped in single packs,they are transferred to the grouping unit,where two CAMA robots pick them up andload the products into the waiting boxes thathave been automatically erected. The boxesare then automatically glued using hot meltadhesive, and closed.Thanks to the strong co-operation betweenCAMA and SPS, it was possible to achieve avery short commissioning time and retainthe high reliability required.The FAT (Final Acceptance Test) wascarried out in Cama’s premises on thecomplete line, making the line easy toassemble and to check the primary and thesecondary packaging machines and robotsynchronisation.This considerably cut the commissioningtime in production, increasing the benefitsto the customer.69

• SPS automatic high-speed LineSPS automatic high-speed line for single products. SPS automatichigh speed feed and packaging line for single products comprises aproductorientation device, a high-speed automatic feeder and acompletely electronic packaging machine SPS Modulo.The packaging line complete with distribution system has been designedfor the completely automatic flow pack packaging of single products,with speeds of up to 1,000 products a minute.• SPS automatic feed system for on-edge biscuit wrappingSPS automatic feed system for on-edge biscuit wrapping.The SPS automatic feed system for on-edge biscuit wrapping ismade up of the new SPS/KFT slug loader and SPS/TGD continuousmotion system for the on-edge insertion of biscuits onto thepackaging machine chain transporter, patented by SPS.The new SPS/KFT loader with SPS/TGD inserter unit and completelyelectronic SPS packaging machine Modulo Boe line representsthe very best available in technology and performance in the highspeedon-edge biscuit wrapping industry.70

• SPS-CAMA complete packaging Linesfrom naked product through to case packingABCIn the Confectionery sector (chocolate/cerealbars) SPS (PFM Group) CAMA will be exhibiting(in a first-ever world preview) a high speedautomatic line, composed of a multiple deltarobot loading unit, combined with a high speedflow-wrapping machine SPS Regola and thenew CAMA compact monoblock loading unit.This new application, being the result of R&Dengineering cooperation, feeds products athigh speed into the vertical race track of thenew compact monoblock loading unit (patentpending). The products are flow-wrappedby the SPS Regola and then packed in acarton and finally inserted into an electroniccase packer. The line is fully automatic, sizechanging can be carried out by the operatorin a completely automatic way, supportedby servo-motor controls and, even better,with no need of tools (ASC - Automatic SizeChanging).DAD• CAMA Robotic DivisionCompact Monoblock Loading UnitForming, Loading, Closing systemSpeed of 60-100 packs/min.• CAMA Robotic DivisionMulti Delta Robots Loading UnitRobots guided by an artificial vision systemInnovative and intuitive “IFEEL PANEL”• Retail ready package solutionWrap-Around Display-box case pakerSpeed: up to 30 cases/min.C71

B• SPS RegolaSPS Regola Horizontal Packaging Machine.The SPS Regola horizontal packaging machineis dedicated to the bakery and confectioneryindustry: completely electronic, designed foraverage packaging speeds (up to 450 PPM),the machine is made up of a special infeedconveyor which enables the machine to be fedby a series of 4-axis robots.The packaging machine, which is integratedinto a robotic cell, is able to wrap single ormultiple products arriving in bulk on the feedbelt. The SPS Regola packaging machine has acantilevered structure and is totally accessibleand can be perfectly sanitised.• SPS B1600 Sandwiching MachineSPS B1600 Sandwiching Machine. The new SPS B1600double-track sandwiching machine represents a furtherdevelopment of the already popular B1600.The new model has been completely redesigned takinginto account the increasingly demanding requirements ofcustomers in terms of cleaning and disinfection of the linewhile maintaining the same high levels of performance interms of speed and production efficiency.72

PFM S.p.A.PACKAGING MACHINERYITALIAN HEADQUARTERSVia Pasubio, 4936036 TORREBELVICINO (VI)ITALYTel: (+39) 0445. 66.22.00Fax: (+39) 0445. 570.175www.pfm.itE-mail: pfm@pfm.itPFM_Lab PFM Group Newsletter - year IV - n° 4Graphic design: areaimmagine.net (Vicenza - Italy)Printing: Tipografia Rumor - VicenzaPFM_Lab is published by PFM S.p.A.All rights reserved. No part of this publication may bereproduced or electronically circulated without theapproval.Non-periodical information not subject to italianlegislation 47/78, also dealt with in legislation 62/2001.Cover: Düsseldorf from Rheinturm, by Frank Kehren.

PFM S.p.A.PACKAGING MACHINERYITALIAN HEADQUARTERSPFMPACKAGING MACHINERY LTDUNITED KINGDOMPFMPACKAGING MACHINERY CORP.NORTH AMERICAPFMOOO "PFM Russia"Verpackungsmaschinen GmbH PACKAGING MACHINERYPFM PACKAGING GROUPPFM IBERICAPACKAGING MACHINERY S.A.PFM PACKAGING GROUPBG PACK S.p.A.PACKAGING MACHINERYPFM PACKAGING GROUPMBP S.r.l.MULTIHEAD WEIGHERSPFM PACKAGING GROUPSPSITALIANA PACK SYSTEMS S.p.A.PFM PACKAGING GROUPPFmeccanicaCOMPONENTS PRODUCTION CENTREPFM PACKAGING GROUPVia Pasubio, 4936036 TORREBELVICINOVICENZAITALYPFM House, 2Pilgrim Way, StanningleyLEEDS - LS28 6LUUNITED KINGDOM1271, Ringwell Ave.NEWMARKETONTARIOCANADA L3Y 7V1Gewerbestraße, 14D-21279 HOLLENSTEDTGERMANYUl. Garibaldi, 36117418 MOSCOWRUSSIACalle Ponent n. 78 - Nave C-6 -Pol. Ind. Can Mascaró08756 LA PALMA DE CERVELLO(Barcelona) - ESPAÑAVia C. A. Dalla Chiesa, 1324048 TREVIOLO (BG)ITALYVia Toscanini, 48/B46043 CASTIGLIONEDELLE STIVIERE (MN) ITALYVia per Cressa28010 BOGOGNO (NO)ITALYVia Casa Celeste, 736014 SANTORSO (VI)ITALYTel: (+39) 0445. 66.22.00Fax: (+39) 0445. 570.175Tel: +44 (0) 113. 23.93.401Fax: +44 (0) 113. 23.93.402Tel: (+1) 905. 836.6709Fax: (+1) 905. 836.7763Tel: (+49) 4165. 221.921Fax: (+49) 4165. 221.922Tel: (+7) 495. 33.11.911Fax: (+7) 495. 71.83.766Tel: (+34) 93. 47.00.910Fax: (+34) 93. 48.09.018Tel: (+39) 035. 20.31.22Fax: (+39) 035. 20.31.25Tel: (+39) 0376. 638.479Fax: (+39) 0376. 670.727Tel: (+39) 0322. 861.100Fax: (+39) 0322. 861.111Tel: (+39) 0445. 570.134Fax: (+39) 0445. 570.175www.pfm.itpfm@pfm.itwww.pfmuk.compfm@pfmuk.comwww.pfmusa.cominfo@pfmusa.comwww.pfmgermany.deinfo@pfmgermany.dewww. pfmrussia.rumoscowpfm@yandex.ruwww.pfm.espfmiberica@pfm.eswww.bgpack.itbgpack@bgpack.itwww.mbp.itinfo@mbp.itwww.spspack.cominfo@spspack.comwww.pfm.itpfm@pfm.itwww.youtube.com/user/PFMPackagingwww.pfm.it74

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