The REV series

syncrofl e xtechnology

etter never stops

THE MOST ADVANCED TRAY SEALERS ON THE MARKET 

packaging automation ltd 

Parkgate Industrial Estate 

1 Montgomery Close 

Knutsford 

Cheshire 

United Kingdom 

• Head Office 

+44 1565 755 000 

• Sales 

+44 1565 756 555 

• info@pal.co.uk

Features 

• Fully electric operation, with zero compressed air 

• Small footprint machine design in single lane format 

• Improved access and visability 

• Ultimate tray control with syncroflex and syncroflexPRO 

• Adaptive film feed system 

• Inbuilt Tool Docking System (TDS and BTDS) 

• Improved hygienic design and construction, with clean 

mode functions 

• Quick release cantilevered conveyors 

• Pack Crush Protection system (PCP) 

• Toolless open access design for hygiene and maintenance 

• Option for Modified Atmospheric Packaging (MAP) 

• Coder integration ready 

• Energy saving – Power Drive 

• Enhanced seal integrity - MAGPAL 

• Dynamic adaptability to keep up as your business changes 

- ‘Flip-it’ capability 

• Industry 4.0 ready

TRAY SEALING 

Fully Electric Automatic Tray Sealers - Where innovation meets efficiency 

The remarkable next-generation REV machine range not only delivers exceptional speed but also features 

full automation, complete electrification, and, powered by our patented PowerDrive technology, operates 

without the need for any compressed air. 

The REV machines are the fastest, most energy efficient and flexible single lane tray sealers 

incorporating our latest technology. Using our proven syncroflex control and now 

syncroflexPRO; we can ensure a continuous flow of trays through the machine from infeed 

to outfeed, eliminating any need for pausing or buffering so maintaining full pack 

stability at maximum speed. Combined with our new intelligent syncroflexPRO the 

adaptive speed control manages all moving parameters automatically increasing 

the machine speed to the rate of packs being fed. Meaning the operator does 

not even have to align machine settings to maximize the output. 

The REV series boasts many features which will benefit the user in 

terms of efficiency, output and reporting.

25% more seal force to meet the 

needs of constantly new emerging 

tray materials 

packaging automation ltd

Energy efficient 

TRAY SEALING 

Fully Electric Operation 

We continue to use our proven patented PowerDrive technology to power the machine. This requires zero air 

and ensures minimum energy is used through the machine in an operating cycle. The latest upgrade to 

PowerDrive is the Energy Reload System (ERS), where we store unused energy from the transfer phase 

(surplus motion energy) in a regenerative power supply and return this energy back to the machine to 

minimise the energy used. 

Following on from our previously reliable patented MAGPAL the seal station now delivers an 

impressive 25% more seal force to meet the development of plastic alternative packaging 

and to reduce packaging seal times.

Using groundbreaking Ai the REV5 

automatically adjusts to the most 

efficient operating speed 


Efficient & optimum speed 

TRAY SEALING 

SyncroflexPRO 

This is the next-generation of machine control and simplifies the set-up for the line operator. The REV series can 

constantly monitor the feed rate of the trays being presented and adjust all aspects of its speed to maximise 

the output. The machine speed is always adapting to the run rate of the incoming trays meaning that 

production is always running as efficiently as possible, and if the incoming tray rate reduces then the 

machine reduces its speed also. Meaning no unnecessary wear or damage to machine parts or 

unneeded energy usage. 

Key benefits 

• Machine speed matches line speed automatically 

• Consistent output means improved productivity 

• Line operator does not limit the speed of the machine

Incoming trays are taken into the 

machine with no stoppages 

increasing efficiency 


Increased pack 

control with optimum output 

TRAY SEALING 

Syncroflex: High-Speed Continuous Stepper 

Accuracy, accuracy, accuracy…. This latest enhancement to the REV series, allows for a continuous feed 

of trays onto the stepper belt without intermittent stops (or stepping movements). This software logic 

provides smooth movement of the tray, controlling each individual tray position and flow into the 

machine. Any tray gaps are consolidated to ensure the maximum speed is achieved, improving 

overall line efficiency. 

Key benefits 

• Increased cycle speeds 

• Slower running belts improve stepping accuracy 

• Pack control and stability reduces tray slips with all trays

Advanced ‘inline seal verification 

system’ to ensure machine is 

operating as it should 


Assured seal integrity 

TRAY SEALING 

Seal Station 

Further developments in the seal operation mean accurate seal positioning resulting in options to monitor and 

feedback with the “inline seal verification system.” The seal stroke has been increased to allow for taller trays 

and added versatility enables the seal speed to be increased as well as a reduction in running noise. 

The seal station has two distinct automatic set-ups ‘high-speed’ and ‘flexible’. 

‘High-speed’ is used for shallower trays where a minimum seal stroke is required and ‘flexible’ 

is used for deeper trays where speed is not so important. The machine has inbuilt 

intelligence to recognise the set-up required and select the correct operating parameters 

automatically. 

Key benefits 

• Increased seal force for cardboard packaging using MAGPAL 

(optional) 

• Increased sealing speed with noise reduction 

• Automatic tool set-up for output optimisation

Seal cycle monitoring smartly 

identifies any potential problems 

allowing for preventative action 

rather than reactive 


Ai monitoring to 

minimise unforeseen breakdowns 

TRAY SEALING 

Inline Seal Verification System 

Originally designed for the medical industry, the servo-driven seal station has the capability to measure and 

monitor the tool seal force prior to commencing any production. Any unseen spring failure or reduction 

of seal force can be detected and verified against the tool recipe notifying the operator of an issue and 

stopping any unsealed trays from progressing through the packaging process. 

Key benefits 

• Seal integrity issues detected prior to sealing 

• Operators guided through the failure process 

• Traceability trending provides historic prompts

packaging automation ltd 

Intuitive machine guidance for 

machine operators

De-skilled interface 

TRAY SEALING 

Operator Interface Screen 

At the business end of the machine the redesigned boom arm is ready to accomodate new and existing coders and 

now employs a simple and uncluttered interface screen for enhanced visability, along with an intuitive userfriendly 

operating system. The updated software offers clear dynamic feedback on the machines current 

status, whilst animated images provide an even more reassuring overview of the machines performance. 

As with all machines they will error so pinpointing issues and providing clear visual representations 

of any faults is important, you can have confidence diagnosing and rectifying any issue with 

minimum downtime. 

Key benefits 

• Intuitive touch screen simple to navigate 

• Animated images help the operator understand 

• Clearly presented faults minimise downtime

Control the 3rd party coder via 

the REV’s HMI screen 


Eliminated coder screen 

TRAY SEALING 

Integrated Coder Software for the HMI 

To keep the operation of the machine simple our software will allow the coding/printing unit to be operated 

through the tray sealer HMI. Access to the coder control page is quick and easy with a recognisable screen 

layout. Mounting of the existing coder interface can be hidden inside the machine to reduce the number 

of operating screens on the production line and potential error. Using the tray sealer HMI provides 

extra security when operated with the RFID access tag system. 

Key benefits 

• Fewer screens to navigate simplifying the operation 

• RFID tags limit the access into the coder information stopping incorrect inputs 

• Existing coder screen is still accessible if required for future requirements

A unique solution in the tray 

sealing industry is the option to run 

the REV in either direction to suit 

the on-site situation 


Ultimately agile - 

operate from either side 

TRAY SEALING 

Versatility and Future-proofing 

In the development of the REV series of machines we also understood an important customer need, to have 

ultimate flexibility and future proof so we came up with ‘Flip-it’. The machine has been designed in such a 

way that the orientation of the machine can be changed at any point. Meaning that instead of products 

travelling from left to right the machine can adapt to products travelling from right to left. This means 

dual machines can then be operated by one person improving output, efficiency and reduction in 

labour. 

Key benefits 

• Machines can be reorientated at a later date 

• One operator has access to two machines simultaneously 

• Less floor space needed

Tool-less conveyor design for more 

efficient maintenance tasks 

and cleaning 


Improved pack movement & 

easy access for maintenance and hygiene 

Infeed/Outfeed Conveyor Cartridges 

TRAY SEALING 

The redesigned conveyor cartridge takes it to a new level and introduces a self-tensioning system, enhancing 

stepping accuracy and minimising slippage caused by contaminants or debris on the belt. The conveyors are 

easily accessible with a quick-release mechanism, making them fully removable without the need for any 

tools or engineering knowledge. The belt can be removed effortlessly without the need to disassemble 

any part of the complete conveyor cartridge. Alternatively, the cartridge pivots smoothly on a gas 

strut mechanism, facilitating easy removal for deep cleaning or maintenance. The redesigned 

cartridges prioritise robustness while remaining lightweight. 

Key benefits 

• Self-tensioning belt system improves stepping accuracy for tray positioning 

• Cleaning and engineering access aided without removing belts 

• Cartridges are lighter to assist removal

Easy to use infeed guidance system 

for precise pack alignment 


Quick & efficient pack alignment & setup 

TRAY SEALING 

Manual Winder Infeed Guides 

Pack presentation to the sealing machine is the most critical part of machine set-up. Centralising infeed 

tray guides on the machine are engineered for manual adjustment, employing a simple reverse-threaded 

screw mechanism. This design allows for precise lateral positioning of the guides to ensure optimal tray 

alignment during the tray feeding process. To ensure the critical settings are kept the tray guides 

can be pivoted away from the infeed conveyor so that easy access can be provided for cleaning or 

removal of the belt. 

For those seeking enhanced automation and ease of use, an upgrade to an automatic 

servo-driven adjustment system is available. 

Key benefits 

• Centralising guides simplify the infeed set-up 

• Pivoting guides allow for critical settings to be maintained 

• Option to upgrade to recipe driven automatic guides

30% more pack engagement from 

a newly designed transfer carriage 


Operate at higher 

speed with greater pack control 

TRAY SEALING 

Transfer Carriage 

A new lightweight carriage has been designed to increase performance and speed. The unique design also offers 

improved rigidity thanks to high performance bearings. Coupled with this new design we have created 30% 

more pack engagement which enables more control when transferring the packs through the machine. 

The transfer arm height adjustment is now inbuilt into the transfer carriage which helps transfer 

the load to the supported area of the carriage and provides a solid and robust foundation for the 

transfer fingers. It also means the tooling is now much simpler and more importantly lighter 

with the height adjustment mechanism relocated to the transfer carriage. 

Key benefits 

• Improved speed and performance 

• High speed bearings provide increased life 

• In-built transfer arm height adjustment means lighter tooling

Comprehensive film monitoring 

ensures smoother production runs 


Increased uptime - fewer film stoppages 

TRAY SEALING 

Complete Motion-controlled Film Feed & Rewind System 

Updated high accuracy film feed and rewind system now has even more control with no wear parts and low 

friction film rollers to reduce film snaps. Variable film tension is continually being monitored by the machine 

to ensure maximum tension throughout the film feeding process. Ergonomically designed to aid the 

loading of the film reel and a film path which allows for easy threading through the rollers during setup. 

Designed as standard with a registered film sensor to recognise pre-printed film marks. 

No mechanical adjustment is required by the operator, as this can be recipe driven 

automatically through the HMI screen reducing the risk of incorrect film set-up. 

On the film feed reel holder, there is an ingenious new reel locking mechanism 

that does not require air and can even clamp damaged cardboard cores. A 

positioning scale is provided as well as a film collar to ensure the film is 

central. 

Key benefits 

• Film snap detection which stops the machine 

• End of reel detection – automatic 10 cycle warning 

• Out of film machine stoppage

Integrated pack spacing system 

to give greater control to upstream 

requirements 


Eliminate bottlenecks 

with a smooth transition 

TRAY SEALING 

Outfeed conveyor system 

An additional conveyor (pacing belt) has been added to the outfeed to provide increased flexibility for 

downstream equipment creating precise gaps between sealed trays. This spacing is crucial when sealing at 

higher speeds for subsequent stages of the production process like check-weighing or metal detecting, 

ensuring that each sealed tray is correctly spaced before leaving the sealer. Such precise gapping helps 

in preventing bottlenecks and ensures a smooth transition through the production line. 

It also provides the capacity for the option to turn the packs from long edge to short edge if the 

downstream equipment requires it. 

Key benefits 

• Consistent tray spacing alleviates bottlenecks downstream 

• At higher speeds the machine can still create tray gaps 

• Option to orientate sealed trays for downstream equipment

Intuitive new safety system aids 

diagnosis of faults and speeds 

up delays 


Intelligent safety monitoring 

TRAY SEALING 

New RFID Guarding 

The REV series has been upgraded with a state of the art safety circuit system. The IP69K rated RFID non-contact 

switches provide an improved safety range as well as a more reliable detection performance as there are no 

moving switches. With the zoned guarding system it ensures machine cycles can be re-started without 

delay after a guard circuit has been broken. Integrated LEDs also allow easy and visible indication of 

current state and diagnosis in the event of a fault. 

Key benefits 

• IP69K as standard protects safety in a wet environment 

• No moving internal parts improve performance and reliability 

• LEDs provide a simple visual status

Eliminating the chances of pack 

smash-ups and costly delays 


Increased uptime 

with reduced pack collisions 

TRAY SEALING 

Tool Pack Block 

The improved Tool Pack Block is seamlessly integrated into the tray sealing machine to prevent any careless 

collisions within the sealing mechanism. It features an intelligent self-taught sensor that automatically halts 

the tray sealing process when it detects any misaligned trays or product protrusions from the tray within 

the base tool, which would normally disrupt the heat sealing operation and require further manual 

input to rectify. This gives the operators the choice to either extract the misaligned trays or leave 

them as they are. With a sample touch on the HMI screen, the machine is then ready to begin 

its cycle once more. The introduction of the Tool Pack Block is a great leap forward to ensure 

cleanliness whilst boosting overall efficiency in performance and productivity on the 

production line. 

Key benefits 

• Can detect any tray in the seal area 

• Reduces downtime due to misaligned trays 

• Can be turned on/off to aid productivity

90% quicker tooling repairs thanks 

to the innovative POD tool design 


Significantly reduced downtime 

for tool changes and tool maintenance 

TRAY SEALING 

Tooling 

We design tooling to ensure it is the lightest it can possibly be without compromising on the ruggedness. Using rubber 

silicone heater elements we provide the assurance that accidental water will not damage the life or operating 

performance. Loading of the tool cannot be any easier with the new inbuilt Tool Docking System (TDS) just ‘Slide 

and Dock.’ The cartridge style POD tooling is modular in design and with the option of a spare cartridge it can 

be interchanged simply and quickly with 2 fixing bolts from the main host plate and can reduce downtime by 

up to 90%. The cartridge also includes a quick release blade system which allows blades to be changed 

in seconds without having to remove the tool from the machine, saving precious production time. 

Base Tool and Fingers? 

Loading of the base is even easier thanks to the new Base Tool Docking System (BTDS). 

Lifting any base manually can be cumbersome so is kept to a minimum with loading 

aided by the latest addition low friction slide plates. Once in position the retained 

base plate locks clamp the base tool into position, simply securing it for 

production. With the transfer arm height adjustment now located on the 

machine carriage the fingers now benefit from a 50% weight saving, 

making them easier to change but also incredibly robust. 

Key benefits 

• New rubber silicone heater mats improve 

reliability, performance 

• Cartridge style PODs save on downtime and 

aid maintenance 

• Simple docking and lightweight 

tooling assist change overs

Monitor all of your Packaging 

Automation lines conveniently 

from your desk 


Efficiency improvement made easy 

Efficiency Beacon 

A light and sound beacon is mounted on top of the machine for improved production visibility. With the EU compliant traffic 

light arrangement, the light tower displays green, amber, red and blue visual lighting for machine status and overall line 

performance. The additional audible sound beacon can be used to warn of stoppages as well as line start-up. The simple 

sound and visual system provides accurate, timely information to the line leader aiding productivity. 

TRAY SEALING 

RFID Fob Access 

Restricts operator access to certain levels within the HMI touch screen preventing unauthorised changes 

to critical functions of the machine. For full traceability and audit trails the system logs all changes and 

which tag/operator made the changes. All tags can be addressed, named and changed on the HMI touch 

screen. 

Miassist Online Dashboard 

The MiAssist system provides live data acquisition and offers a full production management 

tool instantly. The system can be accessed easily through an internet connection, its 

fast, easy to use and gives a straightforward graphical visual of performance at any 

one time. The system offers you the ability to: 

• Track operator real time performance. See a real time visualisation of 

your production assets from anywhere (in the world) with status 

(stopped or running) 

• Immediately see live OEE stats for each line 

• Mobile dashboards allow you to compare OEE stats across 

different products on each line 

• Spot inefficiencies (idle time) quickly to prioritise 

your improvement activities 

• Instantly spot trends and performance 

variations by shift and line 

• Access historic data such as operator 

changes to settings 

• Access historic stats for further 

analysis

Remote access enabling quicker 

diagnosis of problems and 

reducing downtime 


Increased uptime & 

reduced maintenance costs 

TRAY SEALING 

Remote diagnosis module to allow external remote access to the tray sealing machine. Ewon devices initiate a VPN 

tunnel to Industrial Cloud VPN Servers by making an outbound connection. 

Key benefits 

• Eliminate downtime and travel expenses – When problems occur, the machine’s engineer can 

immediately analyse and resolve the issue remotely, limiting costly downtime and travel 

expenses. Using Ewon VPN products, you make it easy for the machine builder to setup and 

control a secure connection to your machines while keeping your corporate network 

integrity secure. 

• Robust, secure and reliable – Thanks to fully redundant and extensive server 

worldwide infrastructure, the Talk2M offers a highly reliable, secure and 

scalable VPN service enabling OEM, machine builders to connect at any time 

from everywhere.

The REV series

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