Tray packing system for fresh fruit salad

Heat-sealing specialists Proseal has devised and installed a bespoke tray packing system for fresh fruit salad at a major fruit processing factory

Each of the three fully integrated lines comprises an automatic tray denester, special 'Fastrax' product delivery conveyor, filling conveyor, Proseal GT1 tray sealer, and outfeed conveyor containing label printer, label verification, check-weigher and metal detector.

Key to the successful integration of all the equipment is the newly developed Proseal Proline-M line management software, which enables the entire line to be set up and controlled from a single Touch Screen on the Proseal GT1.

Proline-M features high performance communication software that can adopt all reliable communication protocols, including RS232 and RS485, and open network connectivity.

As well as enabling complete line set up, it provides comprehensive data from all the equipment for on-going production monitoring and analysis, including yield control management.

In addition, the lines incorporate the new Proseal Prolink, which connects the equipment to the factory LAN (local area network).

This enables operation of the touch screen to be carried out from any connected PC, allowing data to be inputted or corrected remotely.

In addition, Proseal can connect to the system via the Internet to carry out service support or remote diagnostics.

The new lines, which operate at up to 60 trays per minute/hour, feature eight packing stations where fruit is packed by hand.

The 'Fastrax' product delivery system ensures constant product availability at each station, while the automatic tray denester uses fibre optic technology to sense when the next tray is required.

The servo-driven conveyor effectively manages the speed and delivery of the trays to maximise throughput.

Two average weight checking stations check each tray prior to sealing in the Proseal GT1, featuring high accuracy tray positioning and an intelligent film feed system for maximum seal quality.

The GT1 also incorporates a thermal transfer printer for coding of the film.

An extended outfeed conveyor allows application of a clip on lid and the trays then pass through a label printer applicator, which can apply to the top or base of the packs as required, followed by label verification, metal detection and check weighing with a final reject station.

The entire tray packing and sealing operation takes place in the 'High Care' area of the factory.

A special linked belt system then enables the transfer of the sealed and labelled packs to the 'Low Care' area for subsequent case packing and despatch, where no part of the belts from the High Care area runs into the Low Care section.

The modular design of the lines has been created to allow easy removal of parts for cleaning in order to help maintain the highest hygiene standards in the High Care area.

Having already used Proseal tray sealers, the fruit processing company considered the company the obvious choice for this important project.

"We have always been very satisfied with the efficiency and reliability of Proseal equipment and this installation demonstrates their capabilities in devising a bespoke system, tailored to our precise requirements," comments their on-site engineering manager.

"Not only is the line operating well, the Proline-M and Prolink features enable effective line control and real visibility of line performance, and provide invaluable data for production, technical and engineering staff".

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