PV – 3 IN ONE (Compact version)


This is system with 2D printing, vignette labeling, tamper evident labeling and verification systems.

Machine operates at speed up to 60 m / min and capacity of up to 400 boxes / min.

Machine is used in in-line operation. With optional standalone conveyors it can be used also for off-line operation.

Vignette as an option, not quoted. Machine can be later upgraded with vignette labeler. (Upgrading with vignette possible for machine length 1600mm or 1340mm; vignette not possible on machine 1200mm long)

 

 PV – 3 IN ONE Compact 2d, Vig, TE

Automatic machine configured for the application of two tamper evident labels on the closure points of formed cartons; vignette label onto the upper side and printing of 2D code (Datamatrix) and Human Readable data on carton flap, with camera vision control.

 

TECHNICAL DATA

 

  • Ideal for lines with limited space: machine with Vignette labeler, Print and Verify module and Tamper evident labeler
  • Option - software module for Serialization (line level)
  • Completely closed balcony protective housing
  • Positive box transport
  • Pre-arranged for the majority of thermal inkjet printing systems installation
  • Pre-arranged for the majority of OCR, OCV, Human readable data and 2D code verification systems
  • Ergonomic and accessible for easy machine clearance and management
  • Visibility of the production process
  • In-line operation in the packaging line at speed up to 60 m / min and capacity of up to 400 boxes / min
  • Machine's built-length in line is 1600 mm, 1340 mm or 1200 mm (the 1200mm version can have vignette labeler installed)
  • Easy and quick size changeover (no tools needed)
  • Single spindle adjustment of all components in lateral direction adapting to box dimensions
  • A modular concept including printing, vignette and tamper evident applying and verification systems allow easy integration into new or existing packaging lines and combination with equipment from other manufacturers
  • Dimensions of carton boxes: width: 35-120 mm, length 70-240 mm, height 15-130 mm
  • User interface for managing all components through 15" touch screen
  • ERP/MES data transfer
  • 21 CFR part 11 compliant

MODULES

PRINTING AND VERIFICATION

SERIALIZATION LINE LEVEL MODULE

TAMPER EVIDENT LABELING

VIGNETTE LABELING (OPTION FOR 1600 AND 1340mmLONG MACHINES)

PV-3 IN ONE Standard (1600mm)

PV-3 IN ONE Compact (1340mm)

 

Differences (length, max functionalities):

 

    • PV-3 IN ONE
    • 1200 mm long; only Print &Verify and Tamper evident; real diameter 350mm
    • 1340 mm long; Print &Verify, Tamper evident and Vignette labeling*; label real diameter 350mm
    • 1600 mm long; Print &Verify, Tamper evident and Vignette labeling*; label real diameter 400mm

* Vignette is optional. You can order without vignette labeler.


1.           EQUIPMENT SPECIFICATION:

1.1.        MAIN PARTS OF THE MACHINE:

1.1.1.     Infeed accumulation conveyor belt

  • Infeed conveyor belt for the box accumulation
  • Box accumulation area
  • Automatic speed synchronization according to the box dimensions and machine speed
  • Adjustable side guides based on box dimensions

1.1.2.     Transmission mechanism                             

  • Transmission mechanism for controlled handing of boxes from the infeed accumulation conveyor belt on to the main conveyor belt
  • Transmission mechanism synchronizes box handing on to the main conveyor belt depending on the main conveyor belt speed and main conveyor belt rubber teeth position
  • Lateral traction belts move boxes on the main conveyor belt synchronous according to the teeth on the conveyor belt
  • Single spindle adjustment of all components in lateral direction adapting to box dimensions

 1.1.3.     Main flighted belt conveyor

  • Double toothed bottom conveyor belts (left and right) with vulcanized teeth for box transportation
  • Lateral and upper guidance for fixed box transportation
  • Fixed box guidance provides accurate transportation of boxes in lateral direction, box perpendicularity according to transport direction and controlled spacing between boxes which are prerequisites for accurate labels application and imprint positioning
  • Maximum length of boxes (in lateral directions) 240 mm
  • Maximum width of boxes (in the longitudinal direction) 120 mm
  • Belt design allows tamper evident labels application also over the edge of the bottom side of the box
  • Short outfeed conveyor allows controlled transport of boxes from the main toothed conveyor belt onto the conveyor belt of the following device
  • Conveyor belt working height 850 mm +/-50
  • Digital position indicators for fast and repeatable width adjustment
  • Format position is saved in format list and displayed in the HMI
  • Single spindle adjustment of all components in lateral direction adapting to box length

 1.1.4.     Rejection system

  • Non-verified box ejection system based on the results of vignette verification, print verification and tamper evident label presence on the box
  • Tracking each box from verification phase to the rejection
  • Pneumatic ejection (with air nozzle or pneumatic cylinder) of non-verified boxes into the ejection container
  • Ejection container locked with a key
  • Ejection execution controlled with an additional sensor
  • Alarm and optional cartoner stop in case of multiple consecutive negative verifications (adjustable number)

 1.1.5.     Basic frame and protective housing

  • Completely closed balcony protective housing of the entire machine
  • Frame built from aluminum machine building profiles
  • Protective housing and door made of plexiglass
  • Doors with safety switches
  • Specially designed basic frame allows installation and mechanical integration of all functional units - basic transport system for boxes, vignette labeling, printing, tamper evident applying, verification, ejection and all the electrical equipment
  • Stable construction with legs to adjust the working height

 1.1.6.     Electrical equipment

  • Electrical cabinet for machine’s electric equipment installation
  • Stainless steel cabinet, accessible from the back of the machine
  • Power supply connection
  • Elements for power supply and protection of all components
  • SIEMENS SIMATIC S7 1200 PLC for controlling all components and integration of equipment in the entire line process
  • Potential-free relay contacts for signals exchange with an entire line for synchronization of the device with a line
  • 8-port Ethernet switch to connect all components in local area network (PLC controllers, verification systems, printer, computer, etc.)
  • All necessary sensors for machine operation
  • Box tracking along the whole machine
  • Ejection control based on every single verification system
  • Ejection execution control
  • Pressure control of compressed air for ejection
  • All necessary safety switches
  • Emergency stop switch
  • Optical (three colors traffic light) and audible (horn) signaling of the entire plant operation
  • Holders for electrical components installation

 1.1.7.     Integrated information support for machine managing

  • Integrated HMI (human-machine interface) for managing entire device and all the components from a single location (touchscreen)
  • IPC, UPS, 15-inch LCD touchscreen and installed Windows 7 Embedded
  • All components of device (PLC controllers, verification systems, printer, computer, etc.) are connected to the local network, which enables optional connection with remote access in case of troubleshooting, control, configuration and management for complete device and all the components. By assigning remote access rights it enables remote assistance, problem and error locating and total machine maintenance
  • Built-in PC for managing all processes and all relevant data and events, generating reports, communicating with MES/ERP and visualization of all processes
  • 21 CFR part 11 compliant, complete audit trail etc.
  • Device monitoring (status of all individual subsystems, current capacity of the machine, running out / out of media, integrated display of all the warnings and errors from the individual subsystem, drives error, etc.) and based on all these data relevant signalization and reports
  • All events are recorded in the log file. The entire operation history of the machine and all marking processes can be analyzed in case of any problems
  • Enter and change data is accessible only to users with correct user rights with their username and password – accessible to different user levels (eg. operator, technician, technologist, maintainer, administrator)
  • Reports generated in PDF or other formats
  • Content of reports in accordance with the user requirement specifications
  • Reports saving and printing via Ethernet network (network printer via TCP / IP protocol)
  • Keeping statistics: the number of all / good / ejected boxes
  • Service mode for testing and adjustment of the entire machine and individual components
  • All menus in English language (other languages optional)

 

 

1.1.8.     2D cordless handheld scanner:

           

  • 2D cordless handheld scanner for data entering, 2D code checking and optional manual reworks in serialization and aggregation 
  • Datalogic PowerScan scanner
  • Scanner reads 1D and 2D codes
  • Scanner supports reading and sending multiple codes in one reading
  • USB interface
  • Robust housing resistant for drops up to 2m

 

 

1.2.        PRINTING – printing on flap of the carton

 

1.2.1.     Wolke m600 OEM thermal ink-jet printer:

           

  • Industrial ink jet printer based upon HP technology (bubble jet)
  • Print resolution up to 600 dpi
  • Print head height with one head 12,5 mm, upgradeable to up to 4 print heads with up to 50 mm
  • Print speed up to 300 m / min, with 4 text rows and 2D code 60 m / min
  • Incremental encoder for imprinting synchronization depending on the folded box transportation speed
  • Graphic LCD display
  • Device status, warnings and alarms indication
  • Ethernet, USB, RS232 communication interfaces
  • I / O lines for PLC controller connections
  • Printing on all porous materials – unvarnished surface
  • Printing all standard codes, including 2D Datamatrix code
  • Printing variable data from databases
  • Remote access and managing printer through a network
  • Managing printing integrated directly from the common single machine monitor HMI
  • Menus, documentation and instructions in English language (other languages on request)
  • Possible to install up to 4 print heads
  • Possible to install also other thermal inkjet printers

 

 

1.2.2.     Smart Vision camera verification system:

 

  • System configured to verify 2D code and OCR / OCV control of printed text
  • Managing verification integrated directly from the common single machine monitor HMI
  • Software for management and administration of the system
  • Product database including device settings
  • Configurable user levels
  • Simple adjustment for new products
  • Control unit with associated software
  • Possibility to connect up to 4 sensors
  • License for Application module Barcode/Pharmacode and for Application module OCV/OCR
  • Camera AVT Prosilica GC
  • C-mount lens, capture area 60 x 40 mm or as defined (adjusting camera distance from the box)
  • Connection cables
  • Verification system can be extended with additional quality controls - up to 4 cameras for various functions
  • Possible to install all kind of verification systems


 1.2.3.     Stand for camera and printer

 

  • Stand for mounting camera and print head on to the basic machine
  • Positioning the camera and printer head regarding the folded box dimensions and desired print position on the box
  • Threaded spindles for adjusting camera and print head regarding the box height and width
  • Digital position indicators on each threaded spindle for quick and repeatable position adjustment regarding each product dimensions and preferred adjustments

 

1.2.4.     Additional electrical equipment

 

  • Additional electrical equipment will be installed in the main electrical cabinet
  • Elements for power supply and protection of all components
  • Communication with HMI in PC environment
  • Photo sensor for print triggering
  • Photo sensor for camera triggering
  • Components for electrical components assembly and mounting

 

1.2.5.     Additional information support for printing

 

  • Additional software that runs in a separate window in HMI and enables managing folded box printing process – imprinting, verification, ejection, data logging and statistics
  • All components for imprinting (printer, camera) are connected to the local network, which enables the optional connection with remote access in case of troubleshooting, control, configuration and management of complete device and all the components
  • Centralized monitoring of printing process over a HMI (operating mode, machine status, data for imprinting, integrated display of all the warnings and errors, etc.) and based on all these data relevant signalization and reports
  • IT support for printing process and verification of printing, with special emphasis on 2D code and variable data in alphanumeric text imprinting
  • Managing imprinting process through HMI
  • All relevant data logging
  • Statistics on printing and printing verification: the number of all / good / ejected folded boxes
  • All menus in English language (other languages optional)

 

1.2.6.     OPTION - 1 additional print head

 

  • 1 additional print head for Wolke m600
  • 1 addition print head cable
  • Print head plate for 2 print heads
  • Adapter for 2 print heads
  • With 2 print heads max possible print height 25 mm

 

1.3.        TAMPER EVIDENT LABELING

 

1.3.1.     Labeler head IN315 HS Roll – On – split, 2 pcs:

 

  • Automatic tamper evident label applicator
  • Width of labels max. 80 mm
  • Label application speed up to 60 m / min
  • Label roll diameter max. 350 mm
  • Inner label roll diameter 76 mm or on demand
  • Minimum distance between labels 2 mm
  • Labels are applied on folded boxes immediately after unsticking it from liner
  • Label size: label width min. 20 mm, max. 40 mm
  •                   label length min. 15 mm and max. 40 mm
  • Label positioning accuracy + / - 1 mm
  • Longitudinal position of label appliance to the box adjusted through an integrated HMI
  • Setting the height position of the tamper evident label applied on the box (around the edge) by adjusting the labeler head by height with a threaded spindle
  • Unwinding unit with extra traction mechanism for unwinding rolls of labels in a separate loop
  • Unwinding unit is located bellow the machine which makes it easier to manage and reduces the machine’s dimension
  • Additional guidance for managing labeling web from the unwinding loop to the peel bar
  • Rugged stepper motor for main shifting of labels
  • Motor driven winding unit for waste liner, with dancing roller
  • Labeling with transparent or printed labels - photo sensor for transparent materials
  • Labeling head capacity up to 25.000 labels per hour (depending on the speed of box transportation and labels length)
  • Power supply 220V, 50 Hz, 6A
  • Weight 80 kg

 

 

1.3.2.     Tamper evident labels presence verification

    

  • Tamper evident label is attached to the lateral side of the folded box in a way that half of it is attached to the lateral side of the box and another half is unattached (in process of presence verification)
  • Photo sensor detects presence of the unattached half of tamper evident label
  • Box without tamper evident label is tracked and ejected

 

1.3.3.     Assembly for fold down and smooth tamper evident labels over the edge

 

  • Unattached half of the tamper evident label is folded with a specially designed guide
  • Tamper evident label is smooth over with a special roller
  • Precise assemblies for folding guidance adjusting and positioning
  • Height adjustment based on the height of the box for each side separately adjusted
  • Digital position indicators on each threaded spindle for quick and repeatable position adjustment