Thermoforming Modified Atmosphere Packaging (MAP) effectively inhibits microbial growth and slows food oxidation by replacing the gaseous atmosphere within the package. The core equipment that enables this technology is the thermoforming MAP machine. Next, Hansheng Automation will explain the operating principles, core technologies, and key components of this equipment, drawing on its extensive knowledge base of packaging machinery and its practical experience supplying packaging machinery components.
What is the working process of Thermoforming MAP Packaging Machine?
The base film (forming film) and the upper film (lid film) are pulled from reels separately.
After heating, the base film is formed into a box shape using air pressure or stamping in a mold.
The formed boxes are moved between stations for automatic or manual material loading.
The air inside the box is evacuated and then filled with a pre-set mixture of protective gases (such as nitrogen or carbon dioxide).
The upper film is sealed to the formed base box under precisely controlled heat and pressure.
The connected boxes are separated into individual finished products, and scrap material is recovered.
The packaged finished products are conveyed out of the machine.
The core components of the equipment
Servo Drive System
The servo system is the control center and power source of the equipment, responsible for precisely controlling the displacement, speed, and synchronization of each action, including film drawing, forming, and heat sealing. Its performance directly impacts the flatness of the packaging bag, the accuracy of pattern alignment, and the stability of production speed. The DFP series, for example, utilizes a servo motor and control system from Japan's Yaskawa.
Vacuum System
The vacuum pump is the core of modified atmosphere packaging. Its key performance indicators are pumping speed and ultimate vacuum, which directly determine the residual oxygen content within the package. Residual oxygen is the most critical factor affecting food freshness; the lower the better. Relatively good vacuum pumps include the German Busch vacuum pump and the British Edwards Vacuum.
Pneumatic Control System
Pneumatic components (including cylinders, solenoid valves, and pressure reducing valves) are the equipment's actuators, responsible for all actions such as clamping, pushing, opening, and cutting. To ensure long-term stability in the high-load environments of food factories, high-end models generally use pneumatic components from brands such as German FESTO or SMC.
Mold and Heating System
The mold material (such as high-grade aluminum alloy) and processing technology (CNC machining, mirror wire cutting) directly determine the aesthetics, consistency, and cooling efficiency of the finished packaging. Precision molds, combined with high-quality heating rods and temperature control systems, are key to achieving perfect heat seals and smooth, burr-free cut edges. The DFP series molds are formed in a single operation on a machining center and utilize a novel zero-waste punching device.
PLC and Photoelectric Tracking System
The programmable logic controller (PLC) is the brain of the machine, coordinating all operations. The photoelectric tracking system (photoelectric eye) acts like a visual sensor, identifying the cursor on the film and ensuring accurate positioning of the printed pattern (photoelectric registration).
Device Technical Parameters Reference (DFP Series)
|
Parameter / Model |
DFP320 |
DFP420 |
DFP520 |
|
Machine Speed |
15 cycles/min |
15 cycles/min |
15 cycles/min |
|
Rigid Film Packaging - Upper Film Width |
312 mm |
412 mm |
512 mm |
|
Rigid Film Packaging - Lower Film Width |
322 mm |
422 mm |
522 mm |
|
Flexible Film Packaging - Upper Film Width |
292 mm |
392 mm |
492 mm |
|
Flexible Film Packaging - Lower Film Width |
322 mm |
422 mm |
522 mm |
|
Machine Power |
10 kW |
13 kW |
20 kW |
|
Machine Dimensions (L×W×H) |
5100×900×1800 mm |
6150×1200×1900 mm |
6200×1400×1900 mm |
|
Machine Weight |
1300 kg |
1700 kg |
2100 kg |
Why choose high-quality parts?
For example, if your equipment's vacuum pump experiences a problem during use, it can slow down the overall vacuuming process and increase residual oxygen levels, directly impacting the shelf life of your packaged food and affecting production capacity.
Or, perhaps the equipment's pneumatic system is aging, causing malfunctions and unstable pressure during operation, further leading to serious problems such as air leaks, resulting in equipment failure, and frequent downtime for maintenance.
Thus, choosing high-quality parts not only saves you money but also solves hidden problems, ensuring productivity and extending the life of your equipment. Hansheng Automation offers comprehensive parts support. With our own CNC machining center, casting plant, and gear factory, we are your trusted partner.
FAQ
Q: How can I determine if the vacuum pump (or other components) in my equipment needs to be replaced?
A: Vacuum pump: Vacuum pumping time becomes noticeably longer, the preset vacuum level cannot be reached, unusually loud noise levels increase, or oil spray or leaks occur.
Pneumatic components: Slow or stuck cylinder movement, solenoid valve leakage leading to actuator failure, unstable pressure in the equipment's air system.
Servo motor: Positioning inaccuracy (such as diaphragm deviation), unusual noise during operation, and overload alarms.
Q: Is replacing core components like vacuum pumps or servo motors complex? Does it require professional assistance from the manufacturer?
A: Replacing core components requires certain expertise. Although the product comes with installation instructions, we strongly recommend that complex installation and commissioning be performed by your facility's professional equipment maintenance personnel or by hiring a third-party engineer.
Q: Can we purchase individual parts, or must we purchase in bulk?
A: We offer flexible purchasing options. We welcome both trial orders for individual parts and large-volume purchases.
Q: In addition to selling parts, do you provide technical support and after-sales service?
A: Yes. Our team not only sells products but also provides technical consultation and selection services, helping you find the most suitable parts for your older equipment. We also offer after-sales service, including returns, exchanges, and technical support for product quality issues.