Vacuum pump：Daily Maintenance

Vacuum pump, the heart of any kind of vacuum packing machine. We need to take good care of it as we do to our own heart.

Single chamber vacuum packing machine (1 set vacuum pump), double chamber vacuum packing machine (1 set vacuum pump),  automatic belt type vacuum packing machine (1 set vacuum pump), Multi-function thermo form-fill-seal machine (usually 2 sets of vacuum pump)

Vacuum pump maintenance:

• Check vacuum pump oil level and color every week, make sure oil level between ‘MIN’ and ‘MAX’ marks. Either way, you should take action as soon as possible.
• Vacuum pump oil should be clean, shining, without any bubble or being muddy. Or else you should replace all the oil with new oil.
• Check air filter every month
• Do cleaning every half a hear with compressed air: pump chamber, fan engine hood, fan wheel, cooling fin, ventilating grill
• Replace exhaust air filter once every year; clean (with compressed air) or replace air intake filter once every year.
• Replace vacuum pump oil and oil filter every 500-2000 hours or every half a year.

How to choose the right kind of packing film for the food you produce

For a new manufacturer in food industry, it’s always a head-scratching issue to determine the package for your elegant products. You will need to design the appearance of the packs, the printing,  pack size, packing material, sealing method, etc. In this article, let’s talk about the packing material used on multi-function automatic form fill seal machines on the market.

In general, 3 kinds of packing material are widely used in the food packing industry: flexible film, rigid film, aluminum foil.

Firstly, we need to understand the commonly used food packaging terms:

• Barrier Level — means a films ability to prevent moisture from penetrating the film itself
• Clarity degree: means the measurement of a film’s transparency
• Converting: process of cutting a plastic film into lengths, bond the edges, resulting in plastic bags
• Film Gauge: film thickness measured in mils
• Laminated Films: Lamination (bonding together) of two or more films that improves the appearance, barrier level
• Properties Metallized: applying a thin coating of metal to a nonmetallic surface by chemical deposition or by exposing the surface to vaporized metal in a vacuum chamber
• Packaging Films: are melted plastic resin which are extruded into sheets or rolls
• Sealability: bonding process between two layers of film

 LLDPE, short for  LDPE Films Linear Low Density Polyethylene

LLDPE Properties: Inexpensive, good clarity degree

Application: They are often used used to package fresh, produce, frozen foods & baked goods

 HDPE Films: High Density Polyethylene

HDPE Properties: HDPE film is found in many of the same applications as LDPE and LLDPE. it’s stiffer than other PE which makes it an ideal film that needs to hold its shape. High  barrier level for moisture, it is resistant to grease and oils.

Application: HDPE is often used inside a box to preserve its contents such as cereal bags or cake mixes

 PP Films

PP Properties: Soft, clear, glossy, with good moisture barriers & high oxygen transfer rates. Less flexible than LDPE Polypropylene

Application: PP films are often used as plastic food bags in bakeries, and food markets

CPP Films: Cast Polypropylene

CPP Properties: they are easily printable, and run efficiently on packaging equipment like baggers & VFFS

Application: CPP films are used to package baked goods, confectionary items, they’re also used to make flexible & stand up pouches

OPP / BOPP / MET BOPP Films

Properties: BOPP & OPP are the same types of film. The film is stretched in both the machine and transverse directions after it’s extruded, this increases the film’s stiffness, clarity and tensile strength. High resistant to heat and moisture, and has a shiny high gloss appearance. When OPP/BOPP films are laminated with metal foil (MET) it will increase the film’s                                oxygen & water barrier, and block out UV rays Orientated Polypropylene.

Application: Because of the film’s stiffness its used as a wrap for hard candies and chocolates.

PET / Metallized PET

Properties: very good oxygen barrier, heat resistant, strong film with good durability. when PET films are laminated with metal foil it will increase the film’s oxygen- water barrier &   block out UV rays. Metallized films for flexible packaging are essential when the product requires extra protection to ensure a longer shelf life.

Application: MET PET provides protective properties  for food items requiring restricted visibility.

 Nylon Films Properties

Properties and Application:  Nylon film has very good clarity and moisture barriers, is considered a very strong film. Nylon films have a high melting point, they are used for cooking applications such as boiling, microwaves & baking.

Polyolefin Films

Properties and Application: These films are also used for shrink wrapping applications & allow products to stand out when displayed

Common glitches in usage of chamber vacuum packing machines

Chamber vacuum packing machines are designed for home kitchen and small scale business. Both double chamber vacuum packing machine and single chamber vacuum packing machine are widely used by individual person or factory.

Machines always bump into breakdowns,  some are vital while some are just glitches that we can fix by ourselves.

In the following contents, I have a list of glitches and easy solve methods that i want to let you know. ( only for chamber vacuum packing machines)

Problem No.1 : Machine’s not working after chamber lid is pressed.

Reason analysis & Solve:

• Fuse wire is broken  ———– Change fuse wire
• Bad connection of microswitch ——– Adjust the switch chips
• Bad power socket connection
• Power voltage insufficient
• Vacuum time set to 0 which is wrong ———reset vacuum time

Problem No.2: Power indicator light doesn’t work

• Bad connection of power switch ——- replace the switch
• Indicator light broken ——– replace the indicator light

Problem No.3: Vacuum pump is rotating without vacuuming

• Press the chamber lid harder
• The motor reverses —— exchange the power wire
• Check and fix the gas route
• Check and fix or replace magnetic valve

Problem No.4: Vacuum degree too low

• Check somewhere with air leak problem: pipes joints; vacuum pump, vacuum meter, magnetic valve
• Vacuum meter broken
• Bag opening too little for air flow

Problem No.5: Fuse wire broken frequently

• Too  high oil viscosity —- replace oil with appropriate viscosity
• Environment temperature too low —– turn the machine on and warm up for a while
• Drain vacuum pump oil to standard height
• Check if the air draining filter is blocked
• Short circuit in the electric circle

Delivery record of the day -- June 25, 2018

In the early morning of 8:30 AM, the trucks already came. Machines are loaded very fast, we make sure our customers receive them as soon as possible.

1. GB-1000 belt type automatic vacuum packing machine  * 1 set

Heavy Duty Automatic Double Chamber Vacuum Packing Machine DZ-800/2S  * 1 Set 

Very well packed in wrapping film, sending to domestic market

    

2. Heavy Duty Automatic Double Chamber Vacuum Packing Machine DZ-800/2S  * 1 Set 

Well packed in non-fumigated plywood box, sending to seaport, destination Malaysia

Detailed introduction of Multi-Function Horizontal Form-Fill-Seal Machine

Multi-Function Horizontal Form-Fill-Seal Machines are branch seriy of the Form Fill Seal (FFS) machines that are packaging machines that automatically form fill and seal a package on the same machine.

The main types are vertical form fill seal (VFFS) and horizontal form fill seal (HFFS) machines (which is we are going to talk about in this article) – a term often used in the market place to cover horizontal versions of flow-wrappers, sachet machines, blister pack machines, four side seal machines and thermoform fill and seal machines.; in both cases packaging material is fed off a roll, shaped, and sealed. The bags/packs are then filled, sealed and separated.

All modern form fill seal machines are are highly sophisticated featuring computer interfaces and control networks. Greater packing speed and versatility are the major benefits of Form Fill Seal systems for user companies. For example snack producers demand systems that have the versatility to provide fast changeover between many different packaging formats to meet growing demand for single serve packs. Here VERTICAL FFS is capable of creating virtually any size or shape ranging from the standard pillow pack to bags sealed on all four sides.

The multiplicity of FFS machines can use a wide range of material types (including flexible film, rigid film, aluminum foil) and are used across numerous markets including food, drinks, cosmetics, electronics, stationary, tobacco, chemical, medical, and pharmaceuticals.

So the above state is brief introduction of form fill seal machines, as we said, in this article, we are going to talk about the Horizontal form fill seal machine only.

As they might be called in different names (Horizontal form fill seal machine; Thermoforming vacuum packing machine; Automatic thermoformer packing machine; Multi-Function thermoforming packing machine, thermoforming four side seal machine, etc.), we can find the features of this series of machines from their names:

1. Overall shape: The machine is in horizontal structure, compared to the vertical packing machine;
2. Working theory: Thermoforming is the first step to form the container for the products to be packed; next step is product filling/feeding (manually or automatically); next to vacuum and seal, then packs cutting and dispatch. The following flow chart shows the major process of a thermoforming packing machine working schematic:

3. The packs are four sides sealed and cut (Here we are only talking about the thermoforming machine of Kangbeite Food Packaging Machinery Co., Ltd)

4. All the process of the thermoforming vacuum packing machine, (including the components added after the machine was produced

① Bottom container forming process. Working theory: Mechanical punching forming or vacuum forming (by compressed air pressure from upper and vacuum from the bottom)

② Product feeding/filling. The product feeding section size can be customized to leave space for extra automatic feeding system like robot hand, multi-head weighing system, or other automatic weighing machines. With the machines, the thermoforming packing machine is high compatible with any kinds of food processing equipment, so that you can combine them to be a fully automatic food process-package system.

③ After the product feeding/filling section, we are at the sealing film process. According to different packing needs, the sealing film can be stretched or non-stretched, formed or non-formed

④ Next step is the vacuuming and sealing process of the automatic thermoforming vacuum packing machine. In this step, there are also options available, one of which is the most popular Modified Atmosphere Packaging, also as known as MAP packing. In the MAP packing, an extra process is added to fill mixed air to the packs after the process of vacuuming. For details of MAP packing, please check our other article here.

⑤  Next step we come to the optional printing process. You can print dates stamp, or anything. The automatic thermoforming vacuum packing machine is compatible with any kinds of printing system, including inkjet, laser jet, etc.

⑥ The cutting system involves crossing cutting and rolling cutting. For different packing material, and different pack shape requirements, the cutting system is vary. I.E, for the rigid film packs, we don’t use the crossing cutting and rolling cutting system, instead, we use integrated cutting system which is way more expensive but produce better looking packs.

⑦ After cutting process, they final packs are dispatched by the conveying belt to the main conveying belt or crates. That depend on the configuration of your factory.

After all these steps, you will have the final packs finished.

So we know, the thermoforming vacuum packing machine is independent packing line, but it’s not isolated from the production lines. It’s also necessary part of the whole food production line. With appropriate compatibility and configuration, you will gain a high efficiency, stable, easy maintaining food processing line for your factory, which will result in maximum labor save and profit gaining.

How to choose the right vacuum packing machine for your business

There are many varieties of vacuum packing machines in the market, which are widely used in household chicken and industrial level food factories.We will talk about small scale vacuum packer for chicken use a the other time, in this article, we are going to talk about the vacuum packaging machine for food factories only.

Firstly, i’d like to give a brief introduction of vacuum packing machine.

Before that, we need to know what is vacuum packing. Simply put ( Quote from Wikipedia:) Vacuum packing is a method of packaging that removes air from the package prior to sealing.

This method involves (manually or automatically) placing items in a plastic film package, removing air from inside, and sealing the package. (Alternative Modified air packaging is part of the process)

So vacuum packing machine is a series of machines designed to complete the process in good conditions.

Vacuum Packing Machine main varieties (Sort by packing efficiency lower to higher):

• Single chamber vacuum packaging machine
• Double chamber vacuum packaging machine
• Belt type automatic vacuum packaging machine
• Thermoforming (Rollstock) vacuum packaging machine

So now we have the ultimate question, how should I choose the right vacuum packing machine for my business?It’s very simple,  you only need to know 2 things: Know your products to pack, Know the machine to do the packing process. It’s easily said than done, so i’ll explain in the following details.

1. Check the vacuum pump working on the vacuum packing machine. Vacuum pump is the heart of a VACUUM packing machine. It determines the whole quality of the machine, and vacuum degree, vacuuming speed, packing efficiency, everything. We use the world famous BUSCH vacuum pump. which price is several times more expensive than the lower quality vacuum pumps.
2. PLC system and electric components. I call the PLC as the brain, and electric components as the nerve system of the whole vacuum packaging machine. These parts need top quality, high compatibility, and most advanced technology. Usually in a good quality food vacuum packing machine, the following famous brand components are adopted: Mitsubishi, Siemens, Schneider.
3. The main frame and structure should be strong enough and comply with safety&hygienic standards. Main materials for a good quality vacuum packing machine: Food grade SUS304 stainless steel, Magaluma main shaft, Acrylic safety cover for main processes. Whole machine should comply with CE certification and all necessary certifications.
4. Well designed machine structure, with all necessary functions and compatibility for extra functions in further future.
5. Concern about the factory’s after-sale service. Especially for international trade, whether the factory can provide overseas service is very important.
6. Don’t simply make decisions the sales presents talks and the appearance of the machine. You better visit the factory with a technician on your side who can easily judge the quality of the machine.
7. You should know your product: When communicating with the sales representative, you always want them to give an ideal solution for your business as soon as possible. So you should tell them the specification of your products – food or non-food, liquid or powder or solid products, the sizes, the size of your packages, material of the packing bags, the packing method,  your expected packing efficiency, if you need extra functions, if you need the machine in restricted sizes to adapt to your working place, etc

With the above details, you have most of the points to pick the right vacuum packaging machine for your business.

If you are purchasing the machine from abroad, please noted that additional fees will occur, and you need to know the process of importing a product, or you can easily find an import agent from nearby to help you with the work.

What is Modified Atmosphere Packaging (MAP) and why is it so popular?

Brief Introduction

Modified atmosphere packaging (MAP) is a popular way of extending the shelf life of fresh food or non-food products – meat, fruits, vegetables and precise instrument . The MAP process is basically the process if vacuuming the package first, then fill in mixed gas, usually inert gas (nitrogen, co2, etc) at a certain propotion. The mixed gas filled in the package helps ensure that the product will stay fresh for as long as possible, and protect the products by preventing them from direct outer pressure.

Working Theory

The mixture of gases selected to be filled into a MAP package mainly depends on the type of product, the packaging materials and the storage temperature. The atmosphere in an MAP package consists mainly of specified propotion of N₂, O₂, and CO_{2 .} Reduction of O₂ promotes delay in deteriorative reactions in foods such as lipid oxidation, browning reactions and growth of spoilage organisms. Low O₂ levels of 3-5% is used to slow down respiration rate in fruits and vegetables. In the case of red meat, however, high levels of O₂ (∼80%) are used to reduce oxidation of myoglobin and maintain an attractive bright red color of the meat. Meat color enhancement is not required to pork, poultry and cooked meats, therefore, a higher concentration of CO₂ is used to extend the shelf life. Levels higher than 10% of CO₂ are phytotoxic for fruit and vegetables, so CO₂ is maintained below this level. N₂ is mostly used as a filler gas to prevent pack collapse. In addition, it is also used to prevent oxidative rancidity in packaged products such as snack foods by displacing atmospheric air, especially oxygen, therefore extending shelf life. The use of noble gases such as Helium (He), Argon (Ar) and Xenon (Xe) to replace N₂ as the balancing gas in MAP can also be used to preserve and extend the shelf life of fresh and minimally processed fruits and vegetables. Their beneficial effects are due to their higher solubility and diffusivity in water making them more effective in displacing O₂ from cellular sites and enzymatic O₂ receptors.

There has been a debate regarding the use of carbon monoxide (CO) in the packaging of red meat due to its possible toxic effect to packaging workers. Its use however results to a more stable red color of carboxymyoglobin in meat which leads to another concern that it can mask evidence of spoilage in the product.

Packaging materials

Flexible films are commonly used for products such as fresh produce, meats, fish and bread seeing as they provide suitable permeability for gases and water vapor to reach the desired atmosphere. Pre-formed trays are formed and sent to the food packaging facility where they are filled. The package headspace then undergoes modification and sealing. Pre-formed trays are usually more flexible and allow for a broader range of sizes as opposed to thermoformed packaging materials as different tray sizes and colors can be handled without the risk of damaging the package. Thermoformed packaging however is received in the food packaging facility as a roll of sheets. Each sheet is subjected to heat and pressure, and is formed at the packaging station. Following the forming, the package is filled with the product, and then sealed. The advantages that thermoformed packaging materials have over pre-formed trays are mainly cost-related: thermoformed packaging uses 30% to 50% less material, and they are transported as rolls of material. This will amount in significant reduction of manufacturing and transportation costs.

When selecting packaging films for MAP of fruits and vegetables the main characteristics to consider are gas permeability, water vapour transmission rate, mechanical properties, transparency, type of package and sealing reliability. Traditionally used packaging films like LDPE (low-density polyethylene), PVC (polyvinyl chloride), EVA (ethylene-vinyl acetate) and OPP (oriented polypropylene) are not permeable enough for highly respiring products like fresh-cut produce, mushrooms and broccoli. As fruits and vegetables are respiring products, there is a need to transmit gases through the film. Films designed with these properties are called permeable films. Other films, called barrier films, are designed to prevent the exchange of gases and are mainly used with non-respiring products like meat and fish.

MAP films developed to control the humidity level as well as the gas composition in the sealed package are beneficial for the prolonged storage of fresh fruits, vegetables and herbs that are sensitive to moisture. These films are commonly referred to as modified atmosphere/modified humidity packaging (MA/MH)films.

Equipment for MAP packing

In using form-fill-seal packaging machines, the main function is to place the product in a flexible pouch suitable for the desired characteristics of the final product. These pouches can either be pre-formed or thermoformed. The food is introduced into the pouch, the composition of the headspace atmosphere is changed within the package; it is then heat sealed. These types of machines are typically called pillow-wrap, which horizontally or vertically form, fill and seal the product. Form-fill-seal packaging machines are usually used for large scale operations.

In contrast, chamber machines are used for batch processes. A filled pre-formed wrap is filled with the product and introduced into a cavity. The cavity is closed and vacuum is then pulled on the chamber and the modified atmosphere is inserted as desired. Sealing of the package is done through heated sealing bars, and the product is then removed. This batch process is labor intensive and thus requires a longer period of time; however, it is relatively cheaper than packaging machines which are automated.

Additionally, snorkel machines are used to modify the atmosphere within a package after the food has been filled. The product is placed in the packaging material and positioned into the machine without the need of a chamber. A nozzle, which is the snorkel, is then inserted into the packaging material. It pulls a vacuum and then flushes the modified atmosphere into the package. The nozzle is removed and the package is heat sealed. This method is suitable for bulk and large operations.

Multi-function thermoforming packing machine

double chamber vacuum sealer machine

Automatic continuous belt type vacuum packing machine