Media Wrapper

We were approached by one of our clients in the USA to come up with a solution to wrap a number of media cases in film without damaging any parts. Their current machine wraps the cases so tightly together, that a number of cases from each end are always damaged or crushed from sealing.

So we were tasked with collecting cases after the previous operation, stacking a required quantity of cases, wrapping and sealing them and moving them to a collation area for manual packing.

First, the media cases are moved onto a 90 degree air conveyor which uses air flow to move the cases onto an infeed conveyor in a particular orientation so that when the finished pack is completed, the cases are in the required position with the logo at the bottom.


Parts are fed along the in-feed conveyor up to a sensor. When a case is ready at the in-feed to be moved to the transfer station, the stacker unit rotates and picks up the parts from the conveyor using vacuum and places them onto the transfer guides. This process is repeated until a complete stack of cases is created on the transfer guides.

                                                  
Above the transfer guides is a belt with two paddles. The first media case is pushed against the back pressure paddle and the belt moves 1 pitch each time another case is pushed in. When the system has counted all cases, the two outer paddles close behind the last case and then altogether moves the stack along the transfer guides to the push position.

                              

At the cross push position, the parts are placed against an end stop and held in position by the outer paddles on the front of the stack. The whole stack is then pushed through the film curtain. The film curtain is created by grabbing hold of the film end with pneumatic grippers, and pulling down to the required film length and the upper edge of the film is gripped and cut with a flying knife.
The film is held in the film clamp station by vacuum while the pack is pushed through the film curtain onto the folding station.

As the stack moves through the film curtain, the excess film folds around the bottom and top of the stack leaving the sides free to be formed. As following full stacks are transferred and then pushed through, each following stack increments the previous stack by one box length. As the stacks move along the folding plates, the film is folded. First the bottom is folded up and then the top is folded down until they overlap.
At the end of the folding bars, there is a heat sealing station where the heater bars are pneumatically actuated to close in on the stack sealing the film and completing the wrap.


Following sealing, the parts are then complete in the pack and the pack is pushed out of the sealing station on the next cross push actuation.

We were up against another company from the USA that our client had also approached, and even when taking into account the exchange rates and shipping costs, we were the preferred supplier due to them recognising from previous experience, the outstanding levels of support and service we provide during and after the machine has been installed, as well as the reliability and quality of the equipment.

We have already manufactured many machines for this client to de-mould the media cases, close them and transfer them to a cooling area.

             

                               
Unit 3a Swannington Road,
Cottage Lane Industrial Estate,
BroughtonAstley, Leicestershire,
LE9 6TU. United Kingdom