Packaging Material:
Bottom web (flexible) PA/PE
Width: 422 mm (+2 mm)
Thickness: max. 280 µm
Hot seal compliant, draw compliant
Top web (flexible) PA/PE
Width: 420 mm (+/- 1 mm)
Thickness: max. 100 µm
Hot seal compliant
Goods to be packed: not defined
Basic Machine
Consisting of:
Stainless steel construction
Hygienic design (IP 65)
Stainless steel machine frame and side panels are designed according to the
latest hygiene requirements. Side panels are easily removable and accordingly
hinged for cleaning operation. The three-dimensional welded modules have a
maximum stiffness and can be easily cleaned in between the connection points.
Machine chassis
Frame length 3,660 mm
Machine length approx. 4,746 mm
Machine width including cabinet approx. 1,100 mm
Machine height approx. 1,925 mm
Control cabinet width 1,000 x height 1,700 x depth 350 mm
Machine side cladding in loading sector
Nominal machine width 420 mm
Transport chain 5/8" K
Electric basic equipment
Voltage 400 V, frequency 50 Hz, 3 phase(s), with neutral wire and protective
conductor
Power supply with main switch (lockable)
Integrated socket for AC voltage in control cabinet
Emergency stop switch
Safety device SE 005
Integrated safety system (Safety Logic) consisting of:
Safety PLC
Safety sensors and safety actuator
Maximum forming depth 150 mm
Safety shutter shuts before die movement
Product weight max. 4 Kg/cycle
Performance max. 9 cycles/min.
Forming station inlet: safety cover with magnet switch
Forming station outlet: safety flap with magnet switch and photocell
Sealing station inlet: safety flap with magnet switch and photocell
Sealing station outlet: safety cover with magnet switch
Perforated plate safety covers made of stainless steel, Hygienic design
Infeed module ELM 1
Length 1,400 mm
Lifting system Forming
Receiver of forming formats
Pneumatic driven lifting system
Load capacity 20 kN (forming pressure)
Max. opening width 160 mm (lifting bottom/top: 160/0 mm)
Bottom film unwind UF 200, 3" core-Ø (76 mm)
Max. 400 mm diameter of bottom film reel
Adjustable film reel guide, incl. dancer arm system and break
Bottom web forming
Valve block FS 100
Heating with air pressure
Forming with vacuum
Loading module BLM 1
Length 630 mm
Product loading sector
5 open index with index length of 240 mm
4 open index with index length of 270 mm
4 open index with index length of 300 mm
Installation space for vacuum pumps
Sealing module SIM 1
Length 900 mm
Lifting system sealing
Receiver of sealing formats
Pneumatic driven lifting system
Load capacity 20 kN of sealing pressure
Max. opening width 160 mm (lifting bottom/top: 160/0 mm)
Top film unwind OF 200, 3" core-Ø (76 mm)
Max. 400 mm diameter of top film reel
Adjustable film reel guide, incl. dancer arm system and break
Evacuation unit
Valve block EE 100
Edge evacuation
Top and bottom vacuum separately controllable
Pneumatic
Pressure regulator unit R 3/4"
Water separator for air pressure
Safety valve with pressure switch
Sealing valve with pressure regulator
Pressure switch for cooling water circuit
Machine control
IPC 2100 REAL TIME
Industry 4.0 ready
Colored touch screen terminal 12.1"
Stainless steel enclosure IP65
High temperature and vibriation stability
Recipe store for up to 500 recipes
Detailed status indicator of in- and outputs of the PLC visible via HMI
USB interface
Data backup of recipes and machine parameter
Ethernet interface
Password protection - different access level for different access
authorisations
Adjustable main machine data - correctable (password protected)
Adjustable switchpoint for vacuum and gas
Pressure reading
Electronic height adjustment for lifting system in mm: 45, 80, 110, 150
Rate meter
Cycle counter
Detailed fault tracking
4 temperature control loops with off-limit check
Cleaning program with temperature control of dies
Operator language: German
(further languages rapidly available on HMI)
Cutting module SCM 1
Length 730 mm
Installation space for example of cross cutting units, contour cutting units,
longitudinal cutting units, transport systems and film waste handling
Film transport drive FA 100
Frequency inverter 1.5 kW
Perforated plate safety covers made of stainless steel for cutting and
discharge area, Hygiene design
Peripheral equipment:
Forming of bottom web
Valve block FS 200
Heating with vacuum
Forming with vacuum and compressed air
Active carbon filter 0.01 µm for oil free compressed air during forming
Vacuum system VSP000100
BUSCH R5 RA0100F for forming and evacuation
Nominal capacity 100 m³/h
Add-on kit for integrated vacuum pumps
Gas flushing kit BE 100
MAP - inert gas (O2 level < 21%)
Gas tank GT 10, check valve, pressure reducing valve and ball valve
Water circuit blow-off kit KA 100
Automatic blow-off valve for emptying of the die cooling channels
Photoelectric print registration DM 100
Adjustable photocell incl. top web break for flexible top web
Synchronization SC 100
Communication between Hajek packaging machine and up-
or downstream equipment (e.g. marking and inspection units).
Configurable for film transport stop or film advance.
Central lubrication system ZK 100
Automatic chain lubrication
PLC controlled - individually adjustable via HMI
Trim Removal RB 210
Film edge trim
Friction drive with dancer arm system
Transport system AB 100
Discharge conveyor with belt
Height Adjustable
Synchronized drive by film transport chain
Length approx. 900 mm
Cutting systems
2x cross cutter QU 20
Pneumatic driven
Smooth cut from the bottom
Opening width 170 mm (lifting bottom/top: 170/0 mm)
Longtitudinal cutting system LS 10
Motor with preset speed
Suitable for flexible film
Tooling
Cutoff length: 270 mm
Nominal machine width: 420 mm
Edge trim: 39 mm
Forming depth: 150 mm
Basic die
Number tracks: 1
Number rows: 1
Package specification:
Format diagram - DRAFT VERSION
Package dimension: 381 x 270 mm
Forming dimension: 366 x 252 mm
Die components
Forming die lower part
Edge evacuation and gas flush
Designed for forming plates (forming plates are not included in basic die)
Forming die upper part
Heating above forming mould
Tubolar heating element
Non-stick coating
Teflon coating - high quality black
Sealing die lower part
Forming depth: 150 mm
Designed for sealing grid
(sealing grid is not included in basic die)
Basic tool in basic version is not suitable for production of packages.
Vario 1
Number tracks: 3
Number rows: 2
Package specification: EPDM013462
Format diagram - DRAFT VERSION
Package dimension: 127 x 135 mm
Forming dimension: 112 x 117 mm
Package depth: 20 - 150 mm
Product weight: not defined
Performance:
The set performance according to DIN 8743 for this Vario and the above
mentioned machine configuration is approx. 6 - 6.5 cycles/min.
This refers to empty packages, a final vacuum set point of 10 mbar, a forming
depth of 60 mm and without liquid separator.
It depends on the nature of the product and the packaging materials (e.g.
moisture, temperature, oxygen content, etc.) to achieve the vacuum set point
Gas system:
The above mentioned machine configuration is not designed for high oxygen gas
flush with a volume share across 21%.
A special gas flush system (explosion proofed vacuum pump, special valve
technology) is needed, if the volume share is across 21%.
Product: not defined
Film specification:
Bottom web (flexible) PA/PE
Width: 422 mm (+2 mm)
Thickness: approx. 280 µm
Hot seal compliant, draw compliant
Top web (flexible) PA/PE
Width: 420 mm (+/- 1 mm)
Thickness: 100 µm
Hot seal compliant
Vario 1 Die components
6x radius plates
Width 112 mm x length 117 mm x depth 12 mm
Bottom radius 1x R 20 mm
Corner radius 4x R 20 mm
Filling plates for forming depth 20 - 150 mm
Punch for U-shaped evacuation holes, integrated in forming plate
1x Sealing die upper part
Perimeter 5 mm (nominal) sealing seam
1x Sealing grid 3-tracks / 2-rows
Sealing gasket 70 Shore, 3 mm of thickness, fabric finish with 0.8 mm grid
Incl. 4 spare sealing gaskets
1x Set of filler plates, forming depth 70 mm
Package support
Support system in loading section (2 support rail(s) included)
Discharge system (2 discharge rail(s) included)
Vario 1 parts
Longitudinal cutting
Knife magazine consisting of:
1x Knife shaft (MW 10) incl. coupling
4x Circular knife
1x Safety cover incl. handle
1x Cutting register incl. 4 cutting edge(s)
for film support during cutting
General
CE - Declaration of conformity
CE - Sign
Machine labeling: German
Technical documentation
Contents: instruction manual
spare parts catalogue
electrical and pneumatic diagrams