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Hermann WALDNER GmbH & Co. KG
Anton-Waldner-Strae 10 16 Tel. +49 (0)7522 986-34888239 Wangen im Allgu Fax +49 (0)7522 986-419Germany [email protected] www.waldner.de
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Filling and Closing Machines Rotary and Inline Machines
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The WALDNER Group of Companies A Powerful Trio
Today the WALDNER group of companies consists of the following individual branches:
HermannWALDNERGmbH&Co.KG
WALDNERLaboreinrichtungenGmbH&Co.KG
WALDNERLabor-undSchuleinrichtungenGmbH
The quality of WALDNER has been setting standards forawholecenturynow.Accordingtoourcustomersrequirementsweintensivelyuseourpotentialsandexceedthelimitsofourbusi-nessfields.Thus,thethreeWALDNERbranchesstandforstability,experienceandcontinuityreferringtotheirsizeandintegrationintothewholegroupofcompanies.
WALDNERDosomat
WALDNERLaboreinrichtungen
GmbH & Co. KG
WALDNER Labor- und Schul-
einrichtungen GmbH
Hermann WALDNER
GmbH & Co. KG
Dosomat Fll- und Verschliemaschinen
Process Systems
Wassertechnik
TheWALDNERfillingandclosingmachinesareoutstandingduetotheiradvancedtechnology,greatflexibility,enormouscapacityandabove-averageefficiency.
Themachinesaredesignedforanoutputrangebetween1.000 and100.000packagesperhour,dependingonthecustomersrequirements.
TheDOSOMATrotarymachineofthetypes1,2,7,10,12aswellastheDOSOMAT16ASforthesterilefillingofsensitiveproductsareespeciallyappropriateforsmallandmidrangeoutputsandfortheuseofdifferenttypesofpackagesandcontainersizes.Duetotheergonomicquickreleasesystemthechange-overtoanothercuporlidformatcanbeachievedeasilyinafewminutes.
Forlargeroutputrangeswerecommendourhigh-performance inlinemachine,typeDOSOMAT20,whichisalsoavailableas anASversionforthesterilefillingofhighqualityproducts.
AnothermemberoftheDOSOMATfamilyistheUNIMAT,afullyautomaticdosingunit,whichcanbeaccessorisedorfullyintegratedasanadditionalfillingunittoexistingclosingmachines(e.g.cuppingplants).
An overview of the range of machines:
DOSOMATrotarymachine
DOSOMAT inline machine
DOSOMATASforsterilefilling
End-of-linepackingmachines
InterpacGmbH & Co.
www.interpac.de
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Fullyautomaticcupfillingandclosingmachineforfillingavarietyofdifferentproducts intopre-madecups,whichmaybeofplastics,aluminium,carton,coex,tinorglass.Thefillingrangeextendsfromliquidstohighviscosity,powderyproductsorproducts withparticulates.Alsocosmeticandtechnicalproductsarepackedintopre-madecups.Theclosureofthecupsiseffectedbypre-madealuminiumfoils,snap-on-lidsorby sealingaplasticoraluminiumfilmfromrollstockwithintegratedcuttingunit. TheDOSOMATInlinemachinescoveranoutputrangebetween4.000100.000packsperhour.
Machine design
Thebasicframeofthemachineisofamodularconstruction.Theframehousesthedrivinggroupsandthegearboxwhichareeasilyaccessible.Allproductleadingpartsaremadeofstainlesssteelorplasticssuitableforfood.
DOSOMAT20Inline
Dosing systems
Pistondosingsystems InductiveflowmeasuringMassflowmeasuringWeighingdosingsystems (e.g.forfruitormeatpieces, powdersetc.)Pocketfillers(muesli,chunks)AugerfillersRoboticsystems/pick-and- placeoftechnicalarticles, etc.
Theappropriatedosingmethodisavailableforanyproduct.
Drive versions
ServomotorviaELAU PacDriveFrequency-controlledmotorsMechanicaldrivePneumaticdriveOrcombinationsofthese features
Thedrivetrainisbyservomotororbyfrecquency-con-trolledmotor-gear-combina-tions.Forthemaindrivethehightestpriorityisgiventosmoothaccelerationanddecelerationforanyproduct.
Closing Systems
HeatsealingSpecialheatsealingfor aluminiumcups(sterilisable)Hot-melt(cosmetics)Snap-on-lidding,withor withouttamper-proofclosureUltrasonicsealing InductivesealingSealingfromrollstockand lid-cuttingSealingfromrollstockwith integratedlidcutting
DOSOMAT 20.10 AS incl.sterilisationofpackagingmaterial
Capacity:25.000cups/hour Theintegratedcase packeroftheDOSOMAT20inlineassembles,accordingtothepackagingarrangement,thecupsfromtheslatconveyorandplacesthemintothepre-madecartonortray.
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Fully automatic case packer
Theintegratedcasepackertakesthecollationofsinglecupsandstacksthemautomaticallyintothepre-erectedcartons.
This machine is equipped with a sealing from rollstock including print registration
Thesealingfilmisunwound,adjustedbymeansoftheregistrationmarksandsealedtothetray.Inthefurtherprocesslongitudinalandtraverseknivescutoutthesingle-portioncupswithoutleavingresidualmaterial.
DOSOMAT20Compact
Fields of application are: Dressings
Thismachineisprimarilyusedforfillingdressings,mayon-naiseorsimilarproductsintosingle-portioncups.Capacity:10.00040.000cups/hour
Thesingle-portioncupsaredestackedintoatraywith24cells,insertedintotheDOSOMATmachine,filledwithproduct,separatedandfinallypackedincartons.
DOSOMAT 20.24 CompactWithintegratedcasepacker
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ThedelicatessenindustrytrustsinWALDNERDOSOMATmachineswhenitcomestothecarefulfillingandpackingofsaladsorsimilarproducts.Inthiscasethefillingrangeextendsfromsingle-portioncupsuptolargebins,whichcanbefilledwithherringsalad,shrimpsalad,beansalad,coleslaw,potatosaladetc.
DOSOMAT20Delicatessen
Lid magazine/lid setter
Thepre-madeandembossedsealinglidsaretakenfromthemagazineviavacuumsuckersandplacedontothecups.
Thedestackingofthelidsiseffectedbymeansofspecialscrolls,inordertoguaranteeacorrectseparation.Automaticlidscan on missinglid=machinestopsanddisplaysfaultmessage.
Cup feed:
Thecupsetterisloadedfromthelinearbuffermagazine,inastand-aloneversionorintegratedonthemachine,from a cup carousel or from an alternativestoragemagazinespecifiedbythecustomer.
Dependingonthecupmaterialupto1.500cupsperlanecanbestoredinthelinearmaga-zine.Therecupsarefedinstackstothecupsetter.Thesystemassuresanoptimalbuffertimedependantonthemachinespeed.
DOSOMAT 20.6Fillingof1kgcupswithtamper-proofsnap-on-lidsCapacity:16.000cups/hour
Fields of application are: delicatessen
Hygienicdesignandfullflexibilityarethemainrequirementsofthedelicatessenindustry.
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WALDNERDOSOMATmachinesarethemarketleadersintheinnovativefillingandpackingofPat,meat-spread,liversausageetc.intoplasticcupswithre-closablelids.Engineering,constructionandserviceofthemachinesaregivenspecialattentionbyWALDNER.Duetoperfectqualityassurancesystemscanbetracedbackandhencethehighestqualitylevelbecomesastandardfeature.
DOSOMAT20Pat,LuncheonMeat
Sealing unit from rollstock
Withintegratedsealing-/cuttingunitforsealingandcuttingthefilmsimultaneously,including rewinding of skeletalwaste.Aservodrivensealingstationisincluded.Aspecialsealingheadmaterialwithsimilar
propertiestothatoftheconductivityofcopperandresilienceofstainlesssteelisusedinordertoachieveminimumtemperaturefluctuationsandabalancedtemperaturelevelpluslonglife.
Theproductisconveyedtothedosingunitbyvacuumfillerincludingcompensationcylinderandfilledintothecupsthroughaprovenpistondosingsystem,whichincludesaspeciallydesignedrotarycutter.
Inordertoobtainaminimumcontentofresidualoxygenitispossibletoequipthemachinewithaclosedchamberforevacuatingthecupheadspaceandforasubsequentflushofprotectivegas.
DOSOMAT 20.5 withsealingfromrollstock,cupevacuationandgasflushingwithresidualoxygencontentof0,3%
Thecupsaredestackedfromthemagazinebyamechanicallydrivenscrollsystemwhichguaranteesperfectdestackingwithaminiumoffaults.
Thecupsarestabilisedanddrawnintothecupslatwithvacuumassistance.Automaticcupcheck:onmissingcup,themachinestopsanddisplaysafaultmessage.
Cup setter with control unit
Fields of application are: Pat, Luncheon Meat
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Fields of application are: dairy products
FortheDOSOMAT20ASmachinethecupsandlidsaresterilisedwiththemostadvancedtechnology.Thesubsequentstationsarecovered,hermeticallysealedandflushedwithsterileairsoastoavoidanyrecontaminationofthepackaging.
DOSOMAT20ASWithSterilisationofPackagingMaterial
Cup sterilisation
ThesterilisingagenthydrogenperoxideH202issprayedthroughspeciallymanufac-turednozzles.Theatomisedcleaningagentismixedwithaflowofhotsterileairandblownintothecupsviadeliverynozzles.Thisprocessensuresgoodsprayingofthecupswithoutformingdrops,whileanoptimalreactivetemperatureisreached.Thecupsaredriedwithhotsterileaironthefollowingmachinestations.
TheairloadedwithH202 is dischargedexternallyandsafelyawayfromthebuild-ing.Allcleaningmediaarecompletelypreparedinaseparatemodule.
Exactcontrolanddosingofallcomponentsguaranteeoptimaldegerminationrates,whilethemachinesurround-ingswillbelargelyfreeofcontaminationthroughthesterilisingagents.
CIP cleaning / SIP sterilisation
Execution:Thisversionincludesaclosedhopperwithsprayballandelectriclevelcontrol.Theentiredosingunitcanbecleanedinplacewithoutdismantling.Toinitiatethecleaniningprocedure,thecircuitisclosedbymeansofanautomaticlockingcleaningadapter.
Allcomponentsandsealsmeettherequirementsforfoodproductsandcanbeadjusted
tothespecificrequirementsatthecustomer'slocation(3A,EHEDG).TheWALDNERstandardwhichappliestoallCIP/SIPrelevantpartsavoidsdeadlegsandotherpointsofcontamination.Thesterilisationprocedureofthedosingunitiscontrolledthroughsafetychecks(timeandtemperature).Thismeansthatthedosingunitisonlyreturnedtoproduction,whencleaningandsterilisationissuccessfullyachieved.
Lid sterilisation
The aluminium film lids are takenfromthelidmagazine,sterilisedwithstrongultravio-letradiationandplacedonthefilledcups.Forthissterili-sationnon-ozonicprojectorsareused.Asophisticatedaerationsystemusingsterileairallowstheuseofevenplasticfilmlidsonthemachine.
Optionally,infraredorH202 systemsareavailableforsterilisation.
ThesubsequentstationsofDOSOMAT20Inlinearecov-ered,hermeticallysealedandflushedwithsterileairsoastoavoidanyrecontaminationofthelids.
DOSOMAT 20 ASforfillingyoghurtinto1kgbucketsCapacity:9.000cups/hour
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TheDOSOMAT1Compactmachineisarobust,easytohandle,fullyautomaticcupfillingandclosingmachinewhichistheidealsolutionforsmallandmediumcapacities.ThebasicversionisbasedontheexecutionoftheprovenDOSOMATmachine,type1.Themechanicalspeedreaches50cycles/minute.However,theactualspeedofthemachinedependsontheproduct,volume,cupsizeandcupheadspace.
DOSOMAT1.1Compact
Thismachineisappropriateforpre-made,stackablecupswithamaximalformatdiameterof125mmforroundcupsand130x90mmincaseofrectan-gularcups.
Theclosurecanbeeffectedbysealinganaluminiumfilmlid,asnap-on-lidorcombinationsoftheselidtypes.
DOSOMATrotarymachinesareadequateforanoutputrangeof2.50030.000cups/hour.Theyareappropriateforfillingliquids,highviscosityandpowderyproductsorproductswithparticulates.
DOSOMAT1RotaryMachines
DOSOMAT 1Rotarymachinefor14laneswithlaminarairflowcabinet.Capacity:2.50010.000cups/hour
Quickchange-overtoan-othercupformatisachievedbysimplychangingthecupmagazine.
Anewquick-releasesystemofcupcellswithintherotarytableforasimpletoolessformatchange.Sealingstationwithquick-actionclosurecanbefoldedupwards,againtooless.Appropriatefortwodifferentcupdiameters,exchangeofthesealingplateisnotnecessary.
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DOSOMATmachinesarebasedonthelatesttechnologyandconstantdevelopment.Thequalityofourproducts,anexcellentmanufacturingknow-howandtheflexibilitytomeetthecustomersrequirementsthroughindividualsolutionsarethebasicprinciplesofoursuccess.
DOSOMATRotaryMachines
Dosingsystemswithout dirttrapsHose-downexecutionOptimizedCIP/SIPsystemsLaminarairflowcabinetin pharmaceuticalexecution
Sterilisationofpackaging materialstothelateststate ofartEnergyconduits(forair, power,water)areled throughthecornerpillars
DOSOMAT7
DOSOMAT 7Rotarymachinefor16lanesCapacity:2.50015.000cups/hour
Carriage for format parts
Outstandingfeaturesare:
Quickchange-overto anothercupsizeThepossibilitytoruna varietyofdifferentcupsSimpleandelegant operation
Easycleaning(compli- ancewithHACCP-/EHEDG) throughaself-draining design and a minimum ofmovementsthrough themachinetable.
Simple change of cups through quick-release format parts
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Thefollowingexamplesshowsomeproductsthatcanbefilled:naturalandfruityoghurt,yoghurtwithmuesli,cream,quark,freshcheeseandprocessedcheese;avarietyofsalads,soupandsaucepaste,dressings,mayonnaise,mustard,butter,margarine,spreads,honey,jam,pats,petfood,cosmeticcreams,gels
DOSOMATRotaryMachines
Dosing systems: Pistondosingsystems InductiveflowmeasuringMassflowmeterWeighingdosingsystems (e.g.forfruitormeatpieces, powders,etc.)
Pocketfillers(muesli,chunks)AugerfillersRoboticsystems/pick-and- placeoftechnicalarticles
DOSOMAT10
Theappropriatefillingvalvesareavailableforanyproduct,e.g.aspecialrotarycutterforstringypetfood,ortappetvalvesforveryliquidandthinproducts.
AlmostallfillingunitsareavailableinCIP/SIP.
Available in different variations with:
PneumaticdriveMechanicaldriveServomotorFrequency-controlledmotorsOrcombinationsofthese features
Sealing from rollstock
DOSOMAT 10Rotarymachinefor28laneswithsealingfromrollstockandlaminarairflowcabinetCapacity:5.00020.000cups/hour
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DOSOMAT12DOSOMATRotaryMachines
Packaging material
WidelydifferingpackagingmaterialscanbehandledbytheDOSOMATmachines:thecupsorlidsmaybeofpaper,plastic,coex,aluminium,tinorglass.
Discharge of closed cups:
Thecupsareliftedoutofthecupcellsandpushedontoabeltconveyorrespectivelytransferredtoasubsequentmachineortoanintegratedend-of-linepackagingunit.
Integrated case packer
ThecasepackerwhichisintegratedintheDOSOMATmachine,takes,accordingtothepackagingarrangements,thecupsoutofthecupcellsandplacesthemintothepre-madecartonortray.
DOSOMAT 12Highperformancemachinefor212laneswithlaminarairflowcabinetCapacity:5.00030.000cups/hour
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TheDOSOMAT16ASmachinesaresuitableforfillingcupsandbucketsandutilisesofanintegratedsystemforsterilisationofthepackagingmaterial.Capacitydependingonmachineversion:3.00015.000cupsperhour.
DOSOMAT16ASRotaryMachineWithSterilisationofPackagingMaterial
Requirement profile:
Accuratefeedingsystems,cleanroomtechnology,sterilisationofpackagingmaterial,precisedosingunits,reliableclosingtechnology.
Fields of application:
Dairyindustry (yoghurt,milk,cream, kefir,quarketc.)Fruitprocessing (jam,plumandapple pure,etc.)Foodindustry (mustard,spreads, delicatessen,etc.)Non-food (pastes,gels,creams)
DOSOMAT16ASRotaryMachineWithSterilisationofPackagingMaterial
Thelaminarairflowcabinetwiththeprescribedfilterclassescombinedwiththesterilisationofthepackagingmaterialsgiveacleanroomwhichisparti-cularlysuitableforthefollowingapplications:
Useofpackagingmaterial wherecontaminationmay bepresent
Useinroomswithair contaminationwhere mouldsandotherbacteria spreadthroughtheairUseinroomswithlow ceilingandwithahigh aircirculationrateUseinroomwheretraf- ficpassesthrough(loading trucks,transportofgoods)
Bucket sealing from rollstock Cup sterilisation with H2O2
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Our References Our References
Cream CheeseYoghurt /Desserts
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Our References Our References
DelicatessenSaladsButter /Margarine
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Our References Our References
PetFoodMeatPies
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FillingofCosmeticProductsOur References Coffee / Jam / Fruits / TechnicalArticles
DOSOMAT rotary machine withbufferrotarytableandin-feedconveyorforfillingcosmeticproductsintoplasticorglasscups.
