A high speed, straight line, automatic system to glue ply or pouch type pads into solid sheet barrier packaging trays.
The PAD-O-MATIC 300MAP is designed to operate in line with the thermoforming process in the tray production plant.
The design concept is to place a right and left hand PAD-O-MATIC 300MAP downstream of the trim press to provide a
complete in-line system for barrier tray padding with minimal increase in staffing. The trays are taken from the
trim press packaging table and placed on the optional Tray Loading Conveyor, or into the denester magazine of the
PAD-O-MATIC 300MAP. The Tray Loading Conveyor monitors the tray stack height in the denester magazine of the
PAD-O-MATIC 300MAP, and advances a stack of trays on the loading conveyor, and drops them into the denester.
The denester station denests vertical stacks of trays and feeds them onto a single row flight conveyor.
The flight conveyor transports the trays to the pad application unit. At the pad application unit, rolls of
padding material are unwound from dual unwind spindles, which are equipped with constant tension brakes.
The pads are cut to a predetermined length, which is set on the touch screen operator interface, hot melt adhesive
is applied to the tray by an adhesive gun, and the pad is positioned in the tray on the flight conveyor. The padded
tray continues on the flight conveyor to the stacking conveyor. At the stacking conveyor, the padded trays are rotated
to vertical position, counted, the count tray is marked with mechanical striker or optional fluorescent ink, and the trays
are horizontally stacked on the packaging table. The ink is fluoresced by an UV lamp mounted over the packaging table.
The packaging table is equipped with pneumatic bag opening devices to open wicketed polyethylene bags, fast pak bags,
or an unwind can be provided to use rolled, perforated bags. There are guides to allow easy insertion of the stacked,
counted, padded trays into the poly bags. The PAD-O-MATIC 300MAP has an onboard vacuum pump and an automatic pressure
lube system with alarm to lubricate all chains and gears. All electrical meets OSHA and CE standards. The
PAD-O-MATIC 300MAP features single point hand wheel adjustment of the denester width, the machine direction position
of the denester vertical guides, the flight conveyor width, flight conveyor rail height, and stacking conveyor width.
The pad transfer wheel position in relation to the tray on the flight conveyor, the pad position on the pad transfer
wheel, and the pad cut position between pouches may all be adjusted with the machine in production.
The operator interface is a 15" tempered glass touch screen, providing a large format color interface. The main
screen gives the operator control of, and gives status of the following: Registered pad cut, registered pad cut
offset, pad length, vacuum pump and blowers, glue gun, glue swirl air, machine speed, tray count marker, and machine
clear mode. Also displayed are: time and date, glue system ready, guard doors open, and emergency stop engaged.
The recipe screen allows the operator to name, store, and recall recipes for different products. There is a
re-settable display of total trays run, total pads cut, total trays and pads counted, and total rejected by camera
system. There is a control and display screen for the optional tray labeler if ordered with machine.
There is a parameter entry screen for the camera pad verification system if ordered. The operator can call up the
images the camera sees and set up new recopies from the touch screen. The machine encoder timing can be set from
the touch screen without moving the encoder. There is an alarm screen that displays alarms, and an alarm log. There
is a diagnostics screen that displays in real time input and output status of the Acroloop machine control. Each
servo axis has a display showing DAC value and following error, and fault codes from the servo drive.
There is a help screen with a complete online machine manual with troubleshooting, adjustments, and setup instructions
and diagrams. The machine control has a USB port to allow program loading and recipe export using the operator
interface and a USB "thumb drive" without a laptop computer. The control provides for machine shutdown on failure
to denest a preset number of trays, failure to feed a preset number of pads, and denester jam. The control will
provide an alarm and/or shutdown on adhesive system failure and Tray Loading Conveyor jam.
The PAD-O-MATIC 300MAP is available with an auto roll start feature to allow continuous production. When the
production roll of pad material is depleted, the new roll is automatically fed to the pad feed rolls. Using ply
pad material, one tray will have a partial pad that must be removed from the product stream. When running pouch
type pads in the Registered Cut mode, a new roll may be started at production speed without missing a pad in any
tray, if the end of the depleted roll is a good pad. There is also available a labeler option to place pressure
sensitive labels on the bottom of each tray.
Maximum tray width; 10.5 inches. Minimum tray width; 6 inches.
Maximum tray length; 12.5 inches. Minimum tray length; 8 inches.
Maximum tray depth; 3 inches. Minimum tray depth; 1 inch.
Maximum tray depth with deep tray option, 4.75 inches.
PADDING MATERIAL: Ply or pouch type material, 3" wide minimum, 8" wide maximum, 3" long minimum, 9" long maximum,
with a minimum gap between pouches of .5", and a maximum gap of 1.25". Pad length is keypad selectable from 3" minimum
to 9" maximum in .01" increments. Pad cut length with ply pad material is + or - .030 inches. Pad cut length with
pouch pads is dependent on the accuracy of the pad material. Pad placement in tray + or - 1/4" of target position.
Padding material must be wound on a 3" I.D. fiber core to a maximum roll diameter of 38".
PAD CUT SIZE: 3" long X
6" wide minimum; 8" long X 14" wide maximum. Pad length is keypad
selectable from 3" minimum to 8" maximum in .01" increments. Pad placement
in tray + or - 1/4".
ADHESIVE: National Adhesive 34-2950 or equivalent.
Adhesive must be FDA approved for incidental food contact.
MACHINE SIZE: 5 feet wide X 28 feet long. (34 feet long with optional tray loading conveyor)
(37 feet long with optional labeler and tray loading conveyor)
NOISE LEVEL: 82 dB a scale time weighted average maximum.
POWER: 220, 380, 400, or 480 VAC, 3 PHASE, 50 AMP, 50 or 60 HZ (Other voltages