EI BL75 GB 1013 - Cryovac · The BL75 replaces the BL70 and incorporates the latest Sealed Air...

Equipment Information

INDEX:

DESCRIPTION AND KEY FEATURES LAYOUT NOMINAL TECHNICAL DATA CONFIGURATION

Sealed Air Ltd.

Clifton House,1 Marston RoadSt. NeotsGB-Cambridgeshire PE19 2HNUnited Kingdom

Telephone: +44 1480 22 40 00Telefax: +44 1480 22 40 [email protected]

® Reg. U.S. Pat. & TM Off. © Sealed Air Corporation 2014. All rights reserved. Printed in SwitzerlandThe “9 Dot Logo” and “Sealed Air” are registered trademarks of Sealed Air Corporation (US).No part of this manual may be reproduced or transmitted to any party without prior expressed written consent from Sealed Air Corporation.

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1 Description and key features

1.1 Description

The Sealed Air Cryovac® BL75 is a fully automatic, high-speed bag loader for placing consumer and small industrial size foodstuffs (i.e. hard or semi-hard cheese, proc-essed meat) into Cryovac taped bags. It is designed to accept products in-line from the production process and position them directly onto the platens of a Cryovac® 86XX series rotary chamber vacuum packaging machine.

The main elements of the machine are the Infeed Conveyor, the Packing Conveyor, the Bag Handling Tool, the Pusher, the Bag Presenter, the two Outfeed Conveyors, the Bag Trolley, the Electrical Cabinet and the Control Panel.

The machine is made completely of stainless steel, is designed for simple cleaning and meets the highest hygiene standards.

The BL75 replaces the BL70 and incorporates the latest Sealed Air PakFormance® technology. The machine can be used in stand-alone mode or be connected to a PakFormance® network, offering the whole range of PakFormance® functionalities such as:

• Visualization and historical reporting relative to machine, materials and pro-duction performance

• Management of production recipes and machine settings• Remote access

Construction is simple and robust. Designed with ergonomics and safety in mind, the machine is easy to use, simple to maintain and meets all relevant European legisla-tion for safety and hygiene.

Hygiene has played a major roll in the design of the BL75:

• Stainless steel construction with open ‘C’ profiles to avoid contamination going undetected.

• All parts within the product contact area are in stainless steel and have a spe-cial stainless surface treatment

• All areas of the machine are accessible for inspection and are fully washdown.• Latest hygienic design with stainless steel pneumatic cylinders• Motors and gearboxes in high contamination risk areas are of a hygienic stain-

less steel construction with an IP 66/67 rating and fully washdown compliant• All conveyor belts can be quickly removed for inspection and cleaning• Electrical cabinet is equipped with new double sealing to withstand harsh pro-

duction and washdown environment.

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Principle of operation

The product is first fed onto the Infeed Conveyor (CI), and then automatically trans-ferred onto the Packing Conveyor (CPA). The Packing Conveyor (CPA) with mounted Bag Handling Tool (BHT), picks the inflated bag in a telescopic movement from the Bag Presenter (BP). While the product transfers further onto the Packing Conveyor (CPA), the Pusher (PUS) stuffs the product into the bag and completes the loading process. The bagged product is then transferred by Outfeed Conveyor 1 (CO1) where the Product Check (PCK) checks for correct bagging. Outfeed Conveyor 2 (CO2) continuously places and synchronizes the products onto the vac-uum chamber platen of the 86XX.

All conveyor speed adjustments and process control parameters are automatically calculated over full throughput and product range. This allows for easy production changes without changing parameters.

Thanks to integration of the ‘TZ Mode’ functionality, pre-bagged products placed on Outfeed Conveyor 2 (CO2) can also be synchronized with the 86XX rotary vacuum chamber machine allowing for automatic loading onto the platens.

Fig. 1-1, Machine main elements (shown without guarding)

PUS Pusher

CPA Packing Conveyor

BHT Bag Handling Tool

BP Bag Presenter CP Control Panel

PCK Product Check

CO2 Outfeed Conveyor 2

CO1 Outfeed Conveyor 1TRO Bag TrolleyEC Electrical Cabinet

CI Infeed Conveyor

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1.2 Key features

• Fully automatic, high-speed bag loader requiring one operator to monitor only• One machine for both left to right and right to left operation• Machine achieves up to 45 products/min, depending on product type and size• Versatile: can be configured as a single loader - one BL75 feeding one large

unit onto each platen, or as a twin loader - two BL75 feeding two consumer/industrial size units simultaneously onto each platen of a 86XX machine, greatly increasing line capacity

• Can be synchronized with upstream and downstream machines (enables maximum efficiency and eliminates manual intervention)

• Intelligent, self-adjustable conveyor speed and process control over full throughput and product range

• Reciprocating pushers results in a smooth, controlled action for product load-ing and ensures product is loaded to the bottom of the bag

• Modular tooling concept simplifies bag handling tool definition• Quick change of bag handling tool to minimize downtime during product

changeover• Reliable bag opening device for the bag presenter to ensure effective bag ope-

ning and minimize misloading• Integrated product check after bagging, allows final check for correct loading• User-friendly operator interface, full-color touchscreen control panel• Interlocked guards and a category 2 fail safe control system provide state-of-

the-art safety• All belts can be easily removed for cleaning without the use of tools• High level hygienic design makes cleaning easy and effective. Machine is fully

washdown.• Very good access for cleaning and maintenance• Robust, high quality build standard using stainless steel and food approved

plastic materials throughout• Integrated ‘TZ Mode’ for automatic, synchronized 86XX rotary vacuum cham-

ber machine loading of pre-bagged products from Outfeed Conveyor 2• Previous model (BL70) can be replaced without changes to line layout• Practical automation options such as ‘Product Reject’ and ‘Product Positio-

ning’.• PakFormance® compliant• Remote maintenance option for advanced and effective troubleshooting and

software updates

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2 Layout

Fig. 2-2, Layout BL75 with Outfeed Conveyor 2 version:A - 1000 L / 300 W, B - 2000 L / 300 W, C - 3000 L / 300 W

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Fig. 2-3, Layout BL75 with Outfeed Conveyor 2 version 3000 L / 180 W

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3 Nominal technical data

3.1 Machine dimensions

3.2 Weight

3.3 Utilities

3.3.1 Compressed air

3.3.2 Electrical

Length, width & height See machine layout

1400 kg approx.

Air type ISO8573-1:2001 Class 3.4.3

ISO8573-1:2001 Class 3.4.2(when using oils containing esters)

ISO8573-1:2001 Class 3.3.2(when equipment is used below 5°C)

Pressure 0.6 MPa (6 bar)

Consumption 36 Nm³/h

Connection type G ½” external thread

Connection fitting Flexible pipe, 12.5 mm inside diameter

Voltage 400 - 460 V +/-10%

No. of phases 3 phases + earth

Frequency 50/60 Hz

Average consumption 4 kWh max.

Installed power 6 kW max.

Current protection Min. 25 A, max. 32 A,Type C according to IEC 60898-1

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3.4 Working characteristics

3.4.1 Product dimensions

3.4.2 Bag details

3.4.3 Functional details

Length 100 - 400 mm

Width 50 - 250 mm

Height 50 - 170 mm

Weight Up to 7 kg

Note: The product must be stable and able to be easily conveyed through the machine.

Length 200 - 600 mm

Width 130 - 350 mm

Bag type(s) All types with bundling specification WB/WF or PB/PF

Working speed Up to 2 kg: length < 250 mm = 45 ppm2 kg - 4 kg: length < 350 mm = 40 ppm4 kg - 7 kg: length < 400 mm = 25 ppm

Noise level 77 dB (A) at operator’s working position

No. of operators 1 to monitor only

Note: Slippery products may reduce the working speed of the BL75.

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4 Configuration

4.1 Standard

One machine for both left to right and right to left operation with:

• Conveyors equipped with stainless steel drum motors, controlled by inverters• White coloured profiled belts on all conveyors• Product guides on infeed and outfeed• Packing Conveyor (CPA) with stainless steel motor for telescopic movement• Pusher servo drive with two pusher carriages, pneumatic cylinders in stainless

steel• Two pusher arm sets (small and medium)• One bag trolley• Bag presenter for Plug’n Pack• Product check at outfeed• Control panel with full-color touchscreen• Upstream/downstream interface• Outfeed Conveyor 2 (CO2), 1000 mm long, 300 mm wide

Note: Not available for 8600-18 machines• Spare parts kit• Technical manual• Declaration of Conformity

Note: Bag handling tools are not included with the standard machine.

4.2 Versions

Four versions of the machine are available with different Outfeed Conveyor 2 (CO2) lengths and widths, one of which (3000 mm long and 180 mm wide) has been espe-cially designed for a twin configuration production line.

• BL75 with Outfeed Conveyor 2 (CO2), 1000 mm long, 300 mm wide (standard)Note: Not available for 8600-18 machines

• BL75 with Outfeed Conveyor 2 (CO2), 2000 mm long, 300 mm wide• BL75 with Outfeed Conveyor 2 (CO2), 3000 mm long, 300 mm wide• BL75 with Outfeed Conveyor 2 (CO2), 3000 mm long, 180 mm wide

4.3 Options

• Bag handling toolsNote: Bag handling tools must be ordered separately and specified at time of order (refer to section 4.5.2 for important information regarding ordering the correct bag handling tool for the products to be bagged).

• Pusher toolsIn addition to the standard pusher, various pusher arm sets are available for specific applications.Note: Two pusher arm sets are included with the standard machine.

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• Remote access for maintenance (recommended). This option allows for ad-vanced troubleshooting and software updates. Operated via Ethernet; the ma-chine can either be connected through a modem for a point-to-point connec-tion, or preferably for reasons of efficiency, through a DSL router using a VPN (Virtual Private Network).Note: This option includes software provision only.The sourcing of hardware, setup, installation and maintenance of all oth-er required equipment for this option is the customer's responsibility. No Sealed Air support is included with this option.A remote maintenance contract can be discussed at time of order - con-tact the Systems Integration Customization Team in CSC Root.

• Product reject (left or right). This option is not available for the standard ma-chine version because Outfeed Conveyor (CO2) is too short (see option de-tails).

• Reject bin. This option is not available for the standard machine version.• Product positioning for machines 8620-14, 8600-14 and 8600-18• Disc system endless bag feeding - tape wind-up at the bag presenter allows

for ‘endless’ bag feeding and the use of jumbo boxes.• Additional bag trolley to simplify material changeover and material logistics• Product guide for wedge-shaped products (i.e. Grana cheese chunks) special-

ly designed for wedge cuts, allows for reliable infeed product guiding.• Product guide high for round/oval products of height >50 mm• Transfer roller on the packing conveyor, for easy transfer of short products be-

tween the infeed and packing conveyor.• Synchronization utilities for the BL75/86XX interface - this option includes an

indexer sensor with holder to synchronize the BL75 with the rotary chamber vacuum packaging machine.Note: Available on request, this option is ordered together with the 86XX machine - please contact the Customer Service Department.

• Bag inflation airmover for an alternative bag inflation method• Bag detection mechanical for an alternative bag detection method• Roller trolley insert for easy loading of heavy bag boxes• Bag presenter extension to ease inflation of bags with a length ≥550 mm• Differential bag presenter as an alternative bag winding mechanism• Brake curtain outfeed to increase product position accuracy• Installation kit• Blue coloured profiled belts on all conveyors instead of white, to meet specific

hygienic requirements.

4.4 Recommended line assembly

A synchronized upstream conveyor must be used to ensure a controlled supply of products to the BL75 infeed(s).

Single loading:

• BL75 1000/300 + 8600 or 8620 + ST98 + WR81• BL75 2000/300 + 8600 or 8620 + ST98 + WR81• BL75 3000/300 + 8600 or 8620 + ST98 + WR81

Twin loading:

• 2 x BL75 3000/180 + 8600 or 8620 + ST98 + WR81

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4.5 Appendix

4.5.1 Option details

Product reject (left or right) - ‘Product reject left’ rejects the product to the left side. ‘Product reject right’ rejects the product to the right side.

Note: This option is not available for the standard machine version, it is only available for:


Fig. 4-4, Product reject left

Reject bin - specially designed to collect rejected products in a standard plastic box.

Note: This option is not available for the standard machine version, it is only available for:


Fig. 4-5, Reject bin

Product flow

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Product positioning for machines 8620-14, 8600-14 and 8600-18 - mounted on the rotary chamber vacuum packaging machine for final product/bag alignment on the seal bar, controlled by the BL75 controller.

Fig. 4-6, Product positioning on rotary chamber vacuum packaging machine

Product guide high - this option consists of product guides for the machine infeed and outfeed and is designed mainly for round/oval shaped products of height >50 mm.

Fig. 4-7, Product guide high

Transfer roller - is designed for a smooth transfer of small products from the infeed to the packing conveyor.

Fig. 4-8, Transfer roller

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Bag inflation airmover - is an alternative bag inflation method to the air knife and is designed for extremely wet and salty applications. The option consists of two airmov-ers, a mounting bracket and pneumatic connections.

Fig. 4-9, Bag inflation airmover

Bag detection mechanical - is an alternative bag detection method to the optical sensor and is designed for extremely wet and salty applications. The option consists of a mechanical lever and an inductive sensor.

Fig. 4-10, Bag detection mechanical

Roller trolley insert - is a roller arrangement for the floor of the bag trolley, for easy loading of heavy bag boxes (e.g. Jumbo boxes).

Note: Order this option for all additional bag trolleys as required.

Fig. 4-11, Roller trolley insert

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Bag presenter extension - is an extension of the bag presenter to ease inflation of bags with a length ≥550 mm.

Fig. 4-12, Bag presenter extension

Differential bag presenter - is an alternative bag winding mechanism based on the conventional spool system.

Note: This option is not compatible with the conventional spool or Plug’n Pack cassette system.

Fig. 4-13, Differential bag presenter

Brake curtain outfeed - is designed to increase product position accuracy on the platens of the 86XX machine. It is intended for heavy products (>3 kg) and a working speed of >30 ppm for mainly wet and slippery, salty applications. The option consists of a flexible plastic brake curtain positioned over outfeed conveyor 1 and mounting brackets which are installed on the machine frame.

Fig. 4-14, Brake curtain outfeed

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4.5.2 Bag handling tool

The bag handling tool is of modular design and consists of a base, an extension and shovels. Final mechanical adjustment can be made with product and material on commissioning of the machine.

Fig. 4-15, Bag handling tool

The correct bag handling tool with SAP part number YTOOL-27058xx can be selected using the matrix chart. Each bag handling tool covers a certain product dimension range. The selection matrix chart is applicable to all regular rectangular product shapes, for special shapes please ask for customization (contact the Systems Integration Customization Team in CSC Root).

Instructions for ordering the correct bag handling tool

Add 5 - 10 mm to your product width and product height to obtain the correct bag han-dling tool width and height. Select the corresponding range from the matrix chart and order the bag handling tool. The correct part number is indicated at the top of the range. If the product dimension is on the limit, select the next wider or higher range as appropriate.

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Fig. 4-16, Bag handling tool selection matrix chart
Example:

Product shape: rectangular, product dimension: max. width = 100 mm,max. height = 100 mm.

Bag handling tool width = 100 + 5 = 105 mm = within the column 70 - 130 mm range, height = 100 + 5 = 105 = within the row 80 - 110 mm range.

The SAP material number is YTOOL-2705858-V1.

200 mm 200 mm300 mm 390 mm 360 mm 450 mm

Y3222483 Y3222482 Y3222481 Y3222480

170 mm 170 mm

210 mm 300 mm 270 mm 360 mm 330 mm 420 mmY3219137 Y3219136 Y3219128 Y3219127 Y3219257 Y3219256

Y3219133 Y3219132 Y3219126 Y3219125 Y3219253 Y3219252140 mm 140 mm


Y3219133 Y3219132 Y3219126 Y3219125 Y3219253 Y3219252110 mm 110 mm


Y3219116 Y3219115 Y3219186 Y3219185 Y3219122 Y321912180 mm 80 mm


Y3219116 Y3219115 Y3219186 Y3219185 Y3219122 Y321912150 mm 50 mm

70 m

m

130

mm

190

mm

250

mm

YTOOL-2705868-V1 1)

C-5

250

mm

YTOOL-2705866-V1 1)

YTOOL-2705861-V1 YTOOL-2705862-V1 1) YTOOL-2705863-V1 1)

A-3

YTOOL-2705855-V1

B-1

C-4

C-3

C-2

C-1

B-3

B-2

A-1

B-4

YTOOL-2705864-V1 YTOOL-2705865-V1 1)

YTOOL-2705860-V1 1)

A-2

YTOOL-2705859-V1

A-4

YTOOL-2705858-V1

YTOOL-2705867-V1 1)

B-5

130

mm

190

mm

YTOOL-2705857-V1YTOOL-2705856-V1

Armmedium

Armmedium

Armmedium

Armmedium

Armmedium

Armmedium

Armmedium

Armmedium

Armmedium

Armsmall

Armsmall

Armsmall

HIGH = 4

MEDIUM HIGH = 3

MEDIUM LOW = 2

LOW = 1

NARROW = A MEDIUM = B WIDE = C

TOOL WIDTH

1) Check the maximum bag width according to the working characteristics (product dimensions and bag details).

TO

OL

HE

IGH

T

Armmedium

Armmedium

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4.5.3 Pusher tool

In addition to the two standard pusher arm sets included with the standard machine, various pusher tools are available as an option and can be ordered using the follow-ing list.

Pusher profile DescriptionProduct width min.W. p. [mm]

Product height min.H. p. [mm]

Tooling no.Pushercap widthW [mm]

Pushercap heightH [mm]

Standard pusher for medium size products.Included with the standard machine.

80 80 Y2705845 70 70

Standard pusher for small size products.Included with the standard machine.

60 50 Y2705846 55 30

Pusher for large products.

130 80YTOOL-

2706640-V1120 70

Pusher for small, round products.

60 50YTOOL-

2706641-V155 30

Pusher for flat, medium size, round products.

100 50YTOOL-

2706642-V190 30

Pusher for medium size, round products.

100 80YTOOL-

2706643-V190 70

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EI BL75 GB 1013 - Cryovac · The BL75 replaces the BL70 and incorporates the latest Sealed Air...

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