This website uses cookies primarily for visitor analytics. Certain pages will ask you to fill in contact details to receive additional information. On these pages you have the option of having the site log your details for future visits. Indicating you want the site to remember your details will place a cookie on your device. To view our full cookie policy, please click here. You can also view it at any time by going to our Contact Us page.

Atlas ultrasonic technology takes sealing to another level

30 June 2014

Ultrasonic technology uses sound pulses to agitate the molecules within the film; this causes them to vibrate and creates the heat required to seal the pack.

Packs are sealed from the inside out to provide an overall stronger and more homogenous seal.

As well as consistently high quality seals, the ultrasonic technique requires less power, delivering energy savings of over 40% compared to standard heat-generated back and end seal operations. 

At the same time, film usage is substantially less thanks to the sealing depth of the bags being reduced on the end seal from typically 10mm to just 3mm, and on the back seal from typically 13mm to just 6mm.  This equates to a film saving of 11%.  Seals have an improved strength, integrity and consistent appearance even at high speeds.

Like the rest of the Atlas range, the Atlas 203-USS features a user friendly, easy-to-maintain design and is simple to set up and operate.  Sealing operation and time can be easily inputted on the touch screen, allowing the creation of optimum seals for many snack film types.  

The machine is available in either a single or twin tube configuration, with a top speed of 140 bags per minute per tube.

The Atlas 203-USS is available with integrated iTPS™ software, which supports linked operation with Ishida mulithead weighers, throat metal detectors, printers, seal testers and checkweighers to maximise line efficiency.
that keeps it "liquid". If the paddle should stop working, the viscous mass would turn into a solid block of ice that would have to be defrosted in order to remove it from the machine. Like any dairy product, you can't refreeze ice cream that has melted as otherwise there would be a risk of salmonella forming, for example. So if the motor has stopped unexpectedly during the mixing process, the product would be rendered useless. Besides this the ice cream maker would also have wasted all the additives used, as well as the power for the drive and water for cleaning.

Stall prevention in overload range
In order to finally solve this recurring problem, the automation experts from Mitsubishi Electric recommended that the machine builder should test inverters from the FR-E700 series. The integrated stall prevention ensures that the paddle can continue to turn even when the motor is operating within its overload range, as the inverter reduces the output speed for a short time.

First of all, Kälte-Rudi installed an FR-E740 in a prototype and carried out numerous intensive tests. Markus Moosmann explains: "Optimum quality and performance are the bases of our company philosophy. That’s why we were open to carrying out a test run with the Mitsubishi Electric frequency inverters to improve the efficiency and availability of our machines. Tests have shown that the stall prevention can be used to control overloading. If the motor ever goes into its overload range, the inverter will continue to operate at a reduced speed, so the mixing of the ice cream continues and the product remains intact."

With the FR-E700 series inverter, the machine now even continues operation when the motor reaches its performance limits. As a result, the availability of the machine and production efficiency have been improved. Finally, the resource-saving inverter has indirectly contributed to the achievement of savings on additives, power and water consumption. That is important for smaller businesses such as ice cream parlours in particular.

That certain something extra
Kälte-Rudi uses the FR-E720 for 200- to 240-volt operation and the FR-E740 for 380 to 480 volts in its Diagonal Freezer® models. The FR-E700 series covers a power range of 0.55 to 7.5 kilowatts and can withstand high thermal loads of up to 105 degrees Celsius. Sensorless current vector control permits a particularly high level of torque of more than 1:200, especially at the start and end of the process. The speed can be set precisely within a wide range. In addition, the series has a Profibus connection via the optional FR-A7N communication card. The card along with its cover can be connected to the inverter quickly and easily.

Besides stall prevention, the inverter enables a measurable reduction in power, between 15 and 40 per cent depending on the machine and its configuration. "A maximum potential saving on power of 40 percent is quite respectable for motors with an output of up to six kilowatts," remarks Markus Moosmann, who continues: "The Mitsubishi Electric component is much more sophisticated than the competing product that we have used before. The integration, handling and adding optional additional functions such as the Profibus connection are very easy via the connector system. The products are also extremely stable and have convinced us even under the harshest operating conditions. The service provided by Mitsubishi Electric has a strong customer focus. Its employees have a high level of technical competence and respond quickly to our requests and this is supplemented by high product availability. In addition, Mitsubishi Electric's global service network covers all our markets, which is a major advantage if service is required."

Functional requirements met
The network capability with the Profibus connection was particularly important to Kälte-Rudi. It enables the machine building experts to monitor the operation of the inverter in real time at any time. If a problem should occur, the service engineer can tackle it on site by simply connecting a single programming cable to the HMI. No additional special cable is required. Diagnostics blocks can be programmed and any data can be read out via the software immediately.

The integrated safety-off function in accordance with EN 12855 enables a high level of operational safety as the control and regulation circuits of the inverter operate independently from each other. For emergency cases, it provides a safe and direct stop of the paddle.

Outlook for the future
Kälte-Rudi began working with Mitsubishi Electric in mid 2012. Now the Diagonal-Freezer® is equipped with the FR-E700 series inverters as standard. There are plans to expand collaboration further. Due to the very good results with a prototype pasteuriser, also using an FR-E720, the company plans to use the inverter as standard for this machine by the end of 2014. The machine will be completely rebuilt because, until now, a frequency inverter for the pasteuriser was available only as a chargeable option. Thanks to the high level of performance and stability of the inverters, it is possible to use a smaller motor. This reduces costs and energy consumption while retaining the same level of performance. As the next step, modifications to the cream pasteuriser are planned, starting with the building of a prototype. In the medium term, Kälte-Rudi is also intending to use Mitsubishi Electric operating panels and possibly a Mitsubishi Electric control system too. Machine builder Kälte-Rudi has also started work on the development of an ice cream filling machine. With this machine, ice cream makers will be able to offer their classic and extravagant ice cream creations in takeaway boxes, so that they can be easily enjoyed at home. The company is also keen to work closely with Mitsubishi Electric on this project. "The filling machine is a totally new invention, which is currently not available on the market in this way. It will give the automation experts from Mitsubishi Electric the chance to demonstrate their development skills again. The task of filling containers with high-quality, firm ice cream ready for sale is definitely a tricky one," says Markus Moosmann.


Contact Details and Archive...

Print this page | E-mail this page

MOST VIEWED...


Article image Spray and save on the glazing process

Food glazes are widely used in the bakery sector to improve the look and taste of baked products. Traditionally, this coating process has resulted in substantial waste. Technology advances mean that this is no longer the case. Full Story...

Article image Getting the Industry 4.0 journey started

Suzanne Gill finds out why the UK food industry needs to embrace the idea of Industry 4.0 and why the journey needs to start now. Full Story...

Oil-free compressor breaks with tradition

Don’t get left out in the cold this Christmas

Your flexible friend in the food factory

http://www.appetite4eng.co.uk