Efficient full solution line for calibrated products.
Compact and application-based line solutions for calibrated products like deli meat, salami, and ham prove that sometimes ‘less is more’.
As the market leader for full solution lines in slicing applications, Weber is known for its integrated processing and packaging concepts. However, at the Weber booth at this year’s IFFA, visitors were able to see for themselves that the wide range of solutions and services has far more to offer and that Weber customers can expect more from Weber as a system supplier and partner. One of the highlights: A line concept for processing and packaging calibrated products like deli meat, salami and ham, which not only has a minimized footprint, but is perfectly tailored to the technical requirements of standardized product applications. The consistent focus on applications and some new innovative highlights makes the line a perfect solution for economical, yet high-performing production with high outputs.
Right at the start of the line, Weber introduced an innovation that supports the line staff with the manual peeling of round products. The semi-automatic peeling and loading unit allows line operators to insert products into the production line easily, ergonomically, and quickly. It starts with a product guide in which the round products can be inserted before manually cutting the peel and stripping it off. After that, the products are pushed onto a loading unit and buffered there before being loaded. Once the correct number of products is peeled and positioned, the unit is raised by a foot pedal and the products roll onto the infeed module of the slicer.
The Weber thermoformer is full of innovative features.
The thermoforming packaging machine Weber wePACK 7000 integrated in this line concept was customized for calibrated products applications, and despite its compact size, presented numerous technical innovations. One of the reasons for the length-optimized machine configuration is the consistent tracking of individual packages through all process steps. This enables the off-cycle positioning of products during infeeding, labeling or cross-cutting. And the reduced total width of the machine allows for tighter grouping within the cutting station, which prevents module extensions and optimizes machine length.
Going forward, two new technical features of the wePACK 7000 will help prevent downtimes due to film that does not comply with specifications. The first is the new web edge control system, which guarantees the highest operating safety and full utilization of the film width. This is made possible by two sensors and the automatic centering of the film, which prevents film that’s too narrow from slipping out of the chain. The second feature is a new fine adjustment for the chain distance to the sealing station. Necessary mechanical adjustments are still possible without taking up a large amount of time.
To achieve significantly improved shaping of the packages, Weber introduced the new FormTech technology at IFFA. A process called explosion molding ensures even material distribution during the forming process. With a high volume of forming air introduced under higher pressure and in a very short time, this technique helps to ensure the greatest possible stiffness of the packages, particularly when using thin films. In addition, pre-heating is not necessary, which saves valuable line length.
Uncompromising integration and networking.
In addition to innovative and powerful technology, the possibilities of integration and networking result in versatile advantages and added value for food processing companies. These range from an increase in quality and efficiency, to an increase in transparency and process reliability, to the reduction of operator requirements on the line. The unobstructed flow of data enables, for example, targeted portion tracking with automatic corrections to increase efficiency. The line operators can see where each portion is and what condition it’s in at all times. Furthermore, operators can decide how to deal with portions that have incorrect weight. All information, programs and settings can be accessed at one of the control panels at any time and from anywhere. With the help of Weber OneControl technology, it is possible to control the entire line from any operating terminal. This unique software integration even includes third party components. This means that a recipe request always applies to the entire line and the overarching line control via Weber OneControl makes the entire process simpler, faster, and safer. This intelligent multi-directional communication ensures comprehensive future reliability of the line. The intuitive HMI also ensures easy operation.
A further advantage of a completely networked line is the guided batch change. Regardless of whether changing from batch A to B or interrupting the production within a batch: Thanks to Weber OneControl, the batch change is operator controlled via the Weber HMI and optimized for avoiding packaging and product loss. The procedure, which is currently unique in the market, is not only considerably more process-dependable but also much more sustainable and economical, since only few empty rows are produced in the packaging machine, leading to considerable savings in packaging material. But that's not all: in combination with the Weber Digital Factory Solutions, the effectiveness of production can be significantly increased even more and comprehensive transparency of the production process can be ensured. That is true integration, which is truly holistic.
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