Modern dairy and food processing facilities face increasing demands for efficient, hygienic packaging of cream products. Cream case packers automate the process of placing cream containers into cases, reducing manual labor and enhancing throughput. This guide covers essential aspects for manufacturers evaluating cream case packer solutions, focusing on core functions, types, scenarios, price considerations, and strategic purchasing advice. Yanmao Intelligent Equipment (Suzhou) specializes in reliable automation systems tailored for cream packaging needs.
Cream Case Packer Overview and Core Functions
Cream case packers are automated systems designed to handle the precise placement of cream-filled containers into cases. These machines streamline packaging lines for products like whipped cream, sour cream, and cream cheese. Core functions include automated case erecting, container loading, and case sealing. Cream case packers ensure consistent product placement to prevent spills or damage. They incorporate features like adjustable speed controls for varying production rates, typically ranging from 10 to 50 cases per minute. Hygienic design elements, such as stainless steel construction and easy-clean surfaces, meet food safety standards like HACCP and FDA regulations. This automation reduces human error, maintains product integrity during transit, and supports high-volume operations. Yanmao’s cream case packers integrate seamlessly with upstream filling systems for end-to-end efficiency.
Types of Cream Case Packers and Applicable Scenarios
Different cream case packer types cater to diverse operational needs. Semi-automatic case packers require minimal operator input for case loading, ideal for small-scale facilities with lower throughput demands, such as artisanal creameries producing 100-500 units per hour. Fully automatic case packers operate without manual intervention, handling higher speeds of 500-2,000 units per hour; these suit medium to large dairy plants, like those supplying supermarkets. Robotic case packers use articulated arms for flexible handling of irregular container shapes, such as tubs or jars, in complex setups like multi-flavor cream lines. Applicable scenarios vary: semi-automatic models fit budget-conscious startups, while robotic versions excel in high-mix, low-volume environments like specialty food producers. Yanmao offers tailored solutions for scenarios including cold storage facilities, where temperature-resistant components prevent condensation issues, and high-hygiene zones in pharmaceutical-grade cream production.
Price Comparison and Purchasing Strategies for Cream Case Packers
Cream case packer prices range from $15,000 for basic semi-automatic units to over $100,000 for advanced robotic systems. Factors influencing cost include automation level, throughput capacity, and material durability. Semi-automatic models typically cost $15,000-$40,000, offering lower upfront investment but higher labor reliance. Fully automatic case packers fall in the $40,000-$80,000 bracket, balancing efficiency with moderate costs. Robotic case packers, priced at $80,000-$120,000, provide premium flexibility for complex operations. Purchasing strategies involve assessing production volume: facilities with under 500 units per hour may prioritize semi-automatic options, while high-output sites should invest in fully automatic or robotic systems for long-term ROI. Evaluate total cost of ownership, including maintenance and energy consumption; Yanmao’s solutions feature low-energy motors and accessible parts for cost savings. Request detailed quotes based on specific needs, such as case size compatibility or integration with existing lines, to ensure optimal value.
Proper installation and operation ensure peak performance of Yanmao’s automated cream case packers. This comprehensive manual covers essential procedures for food-grade environments, addressing the unique requirements of cream packaging. Following these guidelines maintains hygiene compliance, optimizes equipment lifespan, and minimizes production downtime.
Pre-Installation Preparation and Environmental Requirements
Successful installation begins with thorough site preparation. Verify these environmental conditions before delivery:
– Space Allocation: Minimum clearance of 36 inches (91 cm) on all sides for maintenance access
– Floor Specifications: Level concrete flooring (±1/8 inch per 10 feet tolerance) with vibration-dampening properties
– Utility Connections:
– 200-240V AC power supply (3-phase preferred)
– Compressed air: 80-100 PSI (5.5-6.9 bar), filtered to 5 microns
– Data ports for PLC integration
– Environmental Controls:
– Temperature range: 50°F-77°F (10°C-25°C)
– Humidity below 60% RH to prevent condensation
– Positive air pressure in packaging areas
– Safety Compliance: OSHA-compliant emergency stop circuits within 15 feet (4.6 m)
Conduct material readiness checks:
– Food-grade lubricants (NSF H1 certified)
– Sanitation kits with CIP-compatible cleaning solutions
– Manufacturer-provided mounting hardware
Step-by-Step Installation Guide for Automated Cream Case Packers
Execute installation in sequence for optimal alignment:
-
Uncrating and Positioning
– Remove transit braces using provided torque wrenches
– Position machine using air skates (never drag)
– Verify levelness with laser alignment tools (±0.5° tolerance) -
Mechanical Assembly
– Mount case conveyor sections with gap sensors
– Install servo-driven container grippers
– Attach vision-guided positioning system -
Utility Connections
– Connect air lines with quick-disconnect fittings
– Wire power through shielded conduits
– Establish Ethernet/IP communication to plant SCADA -
Calibration Procedures
– Laser-align case transit pathways
– Program container detection sensors
– Test gripper pressure settings (5-7 psi for cream containers) -
Validation Testing
– Run empty cycle at 50% speed
– Conduct load tests with dummy containers
– Verify emergency stop functionality
Operation Procedures, Maintenance, and Troubleshooting
Standard Operating Protocol
-
Startup Sequence:
– Engage main power switch
– Initiate HMI interface
– Select cream container profile
– Activate auto-mode after conveyor synchronization -
Production Operation:
– Monitor throughput via dashboard (ideal: 40-60 cases/minute)
– Verify case sealing integrity every 2 hours
– Record temperature logs hourly -
Shutdown Procedure:
– Complete in-process cases
– Execute automated purge cycle
– Apply food-safe corrosion inhibitor
Maintenance Schedule
| Frequency | Task | Critical Checkpoints |
|---|---|---|
| Daily | Surface sanitization | No residue in product zones |
| Weekly | Lubricate guide rails | NSF H1 grease application |
| Monthly | Belt tension verification | ±5% factory specification |
| Quarterly | Sensor calibration | 2mm detection accuracy |
Common Fault Resolution
-
Containers Misaligned:
– Recalibrate vision system
– Check vacuum gripper seals -
Inconsistent Case Sealing:
– Verify adhesive temperature (150°F±5°F)
– Inspect tape feed tension -
Throughput Reduction:
– Clean optical sensors with alcohol wipes
– Examine conveyor drive chains -
Emergency Stop Activation:
– Reset main power after clearing obstruction
– Confirm safety curtain alignment
For persistent issues, contact Yanmao support: [email protected] with error codes from HMI diagnostics.