A revolution on the traysealers market. This is a new traysealer REV5!

Zgrzewarka REV5, Traysealer REV5

The Packaging Automation Ltd added this year a new traysealer REV5 – to their product range. The British manufacturer declares that in many respects this traysealer exceeds the previous traysealer models and introduces a new quality to the market of sealing with heat-shrinkable film. Let us check, what are the characteristics of this machine and who are the addressees of the new REV5 traysealer.

REV series: a revolution in sealing high packaging volumes

REV is a new series of traysealers, one of the most advanced pieces of this type of equipment on the market. The Packaging Automation Ltd (PA) has been creating machines for more than 60 years. REV5 is based on impressive manufacturer’s achievements, and, in addition, uses state-of-the-art technologies, including the artificial intelligence (AI). Because of this combination, we obtain the equipment which allows to shrink-wrap even faster, more efficient and productive, which translates into better financial results of the company.

The new ace in the PA deck features extraordinary productivity and speed of package wrapping. This is a machine designed for big production plants, where the speed and effectiveness of operation are important. The machine allows to seal various types of packaging – made of plastic, pulp, and cardboard – of various shapes and capacities. In recent years the traysealing technology, that is wrapping the packaging with heat-shrinkable film, gains popularity. Its importance grows, which results from the trend aimed at plastics reduction. Even more, the film layer is lighter and cheaper than a plastic lid and at the same time it well protects the product inside.

These arguments convince the decision makers in retails chains, who eagerly reach for the products packed just in this way. So, a traysealer is a solution for food producers, who are willing to sell their products to big players (supermarkets, discount retailers). Such closing of packaging is popular in the fish and meat sector, although from our point of view it is worth noting that this closing technology is doing better and better in the fruits and vegetables sector, successively displacing lids.

Main trump cards of the REV5 traysealer

  • The speed of operation higher by 20%
  • Overall equipment effectiveness (OEE) increased by 30%
  • Energy saving (even by 50%) due to the proprietary technologies: PowerDrive and Energy Reload System
  • Developed systems of process control, which use AI – detection of potential errors in advance and the cycle breaking in case of irregularities occurrence
  • Improved performance at simultaneous reduction of noise generated by the traysealer
  • Advanced technology in an intuitive, operator friendly form
  • Easier access to individual components – faster cleaning and maintenance
  • Flexibility: a possibility to operate in both directions
  • An intelligent system for the operating speed control, adapting to the rate of packaging feeding

REV5: tray sealing driven by technology

The PA engineers have developed a machine which is fully automated and operates without the need for the compressed air delivery. The optimal management of the energy consumption is its characteristic feature due to the application of PowerDrive and Energy Reload System (ERS) technologies. As a result, the users receive the fastest sealer in its class, most productive in energy terms, and extremely flexible regarding the spectrum of sealed types of packaging. The traysealer developers managed, e.g., to improve the seal quality by 25%, which is a response to the changing trends in the packaging market, and also to shorten the time of sealing process, and at the same time to maintain high tightness of the seal.

REV5 traysealer: artificial intelligence, real effects

The machine uses the SyncroflexPRO AI module, which monitors the number of packages fed to the sealer and based on their frequency it adapts the speed of machine operation. It translates into no shut-downs, process continuity, and lower energy consumption. Furthermore, the continuity of packages feeding has been improved in the REV5 as well as the control of their position and distances between individual trays. An increased speed of sealing cycles and reduction of breaks in operation are the effect. In addition, the machine can operate in two sealing formats: ‘High-speed’ and ‘Flexible’. The first works better at shallow trays and the second at deeper packages, where the speed is not that important. The traysealer automatically recognises and applies the optimal sealing mode.

Caring of the production continuity

A British saying ‘Safety first’ is also reflected in the REV5, although in this case we refer mainly to the ensuring of the production process continuation. This modern sealer has been equipped with systems, which monitor the machine operation. For example, the machine analyses and adapts the strength of sealing to the type of packaging before the production starts. In addition, it controls the state of sealing film tension. Because of that, failures, which are not visible by a naked eye, may be eliminated before the cycle starts. A laser, which breaks the process in case of packaging disarrangement in the seal bed, is another protection. Touchless RFID safety switches (IP69K standard) ensure an increased scope of safety and restarting the cycle without delays after the circuit closing. Additional protections also apply to the film roll – the machine detects the film breaking, informs the operator of a low film reserve on the roll and stops the cycle, when the film ends.

Traysealer REV5 zgrzewarka jednokierunkowa

Single lane, two directions

Contrary to the competitive sealers, the REV5 is a single lane machine, due to which it requires much less space than two-lane machines, which simply have larger dimensions. This is not the only challenge faced by the users of two-lane traysealers. Their seal beds are much heavier, and their replacement is complicated. What is important, at a two-lane sealer it is necessary to separate one packaging feeding line into two and next join them into one line directing the packages to the labeller. It generates additional costs in the form of conveyors purchase.

At the same time, the REV5 traysealer is very flexible. It can successfully seal various packaging types, but also it has been equipped with a Flip-it system. Because of this solution, the machine orientation can be changed at any moment and the packages for sealing can move from the right to the left side or from the left to right side.

Intuitive software valued by the users

At a very high level of the technological sophistication, the REV5 traysealer remains a machine relatively simple in operation. An intuitive and ergonomic interface, a touch screen (HMI) available from both sides of the sealer, used to control the machine, should be credited with that. The software applied by the PA provides the data in a very accessible form – the information describing the current process, and it also provides hints related to potential errors. For that reason, the operators can work pro-actively and eliminate threats leading to costly standstills.

Traysealer REV5, Zgrzewarka REV5 traysealer ekran dotykowy

Ergonomics and easy access

In the REV5 the PA designers make big compliment to operators and service technicians. Many components of the machine feature tool-less access, which facilitates the machine changeover, cleaning and sub-assemblies replacement. Because of that, the processes, which do not translate into the company’s financial result, and at the same time are necessary during the production, take less time. Quick changeover of support conveyors or arms directing the packages are examples of such a solution.

Traysealer: an innovative design of the machine

At the end let us have a look at the REV5 construction. The features, which are worth noticing, include cantilevers supporting the conveyors on both sides of the packaging sealing station. The PA designers decided to apply a limited shielding (as practised by the competition) to achieve better access and easier cleaning of those machine parts. The location of drives atop facilitates the maintenance operations and prevents an accidental contact of the electronics with water. The main side panels were made of hard-anodised aluminium, covered with a PTFE coating. Such a combination is highly resistant to the action of cleaners and to scratching. Details have been designed with easy cleaning in mind (rounded shapes and no unnecessary projections). The anti-vibration feet of the machine have been widened and elongated, which translates into better stabilisation of the sealer at full speed operation.

Traysealer in an extended version

Apart from the aforementioned solutions built-in in the REV5, the manufacturer provides a possibility of configuring an own version enhanced with additions. The options include a signalling tower assembled on the machine, a system for remote monitoring of processes, MiAssist, protection of selected machine functions by limited access to the monitor managing the traysealer, a passive conveyor, on which packaging closed with a lid or trays that do not require sealing are transported through the machine, and also filling the packages with a special gas mixture instead of the air.

REV5 traysealer – let us get to know each other closer

The new REV5 traysealer is a really advanced machine, which provides many possibilities for companies sealing the packages with a heat-shrinkable film. It is difficult to discuss all its advantages in a text form. Therefore, we invite you to fill in the form and to arrange a free consultation with a Milbor PMC’s expert. During the discussion you will learn a full range of REV5 values, and you will find, whether this machine best corresponds to the production challenges, which you face.

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