Elevating Hummus For Efficient Throughput
Our NCP-25 automated case packer handling various sizes of hummus containers (10, 12, 17, 24, and 32 oz). The machine operates with alpine accumulation, packing at a rate of 160 products per minute. The equipment efficiently collates, and packs the containers into cases, demonstrating high-speed automation and precision in the packaging process.
Collaboration with key partners
Rychiger collaborates with a range of technology partners and offers customized, efficient, and high-speed packaging solutions to meet the diverse needs of the industry. As an example in this video, we integrated alpine accumulation, and QR code verification system. This is just one example of the many auxiliary components that we can integrate to provide turnkey solutions to our clients, some of these include checkweighers, printers, accumulators, labelling equipment, stretch wrappers and many more.
Inline Quality Control
At the onset of the video, you will notice the containers are passing through an array of scanners. This in-house system utilizes Cognex scanners and a vision camera to detect recipe specific identifiers on the container. On the side of the container there is a label with a unique QR code, which contains the information of the package. The lid has a label applied with the product name and QR code identifier. The system will locate the QR code on the two surfaces, scan it and compare it with the prescribed recipe. While doing so it will also identify features on the lid to confirm its presence. With integrated reject, it prevents various non-conforming product from entering the system and being released into the market. We are also an ISO 9001 certified company, and we maintain the highest standards and documented processes from sales to design, assembly to installation and the service of our equipment.
The NCP-25 case packer is our ultimate all in one – single frame solution with integrated case erector, product collation, loading, and case sealing. Handling this type of product with the case and pack pattern varieties require for this market in a best-in-class footprint. The container sizes range from 10 to 32 oz with multiple diameters and heights. This is one of our best-selling machines and can handle a variety of standard deli and square containers. The case erector utilizes a mechanical system to erect the RSC cases but can be fitted with a vacuum solution for thinner cases. It can work with various corrugated fluting material including B, C and E-flute. The integrated case erector as seen functions with tape to seal the cases (2” or 3”), while it can also be fitted with a glue system as an option
Downtime Reduction Strategy
This system in particular displays an alpine accumulation solution that will divert the product to keep the filler in operation during a down stream stoppage and re-introduce the product back on the line upon restart. This provides about 4 minutes of buffer to address a routine stoppage downstream, to replace the tape head, a slip sheet magazine, or reset a minor fault. The restart creates a surge speed into the case packer that it will handle to clear the accumulation buffer.
Optimal Reach and Payload
The product loading is executed with a Codian D2 robot controlled by an in-house Allen Bradley (Rockwell) motion platform. They are also integrated with several sizes for optimal reach and payload. The unit illustrated in the video can handle a payload of up to 220 pounds (including tooling). The end of arm tooling for this application is a proprietary design utilizing vacuum to lift the product while also mechanically locking the lid against the container. This solves a common industry problem of mismatching lids and containers with variable tolerances. The cases are loaded 2 or 4 at a time depending on the pack pattern, to maintain the throughput.
Once loaded the cases are sealed with tape on the integrated case sealer. Similar to the case erector, this system also offers a glue seal option. The entire system is designed with full height frame and guarding with ease of access and maintenance in mind. The unit is a unique solution for a single frame, single control platform that allows it to fit in tight spaces. Combined with our robotic palletizer our customer received a complete turnkey solution for hummus.
Our single cell case packers handle a wide range of products and various industries ranging from 5 to 25 cases per minute and product speed reaching upwards of 500 products per minute. Our customers automation endeavors are an attempt to improve process efficiency, throughput, product quality, ergonomics, and/or floor space constraints.
