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Maker - Product Challenge

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<span style="font-weight: 400">At last, you reached the final stage of processing your product - welcome to the packing world! Packing preserves and protects a product from damage, spoilage, and contamination while it makes its way from the production line to the consumer or further production. Depending on which industry your products belong to, the type of primary packaging equipment can change drastically. You need to pay careful attention to products with </span><span style="font-weight: 400">chemicals or hazardous substances since they can be potentially dangerous to human health. </span>

Packing

Peanuts, also known as groundnuts are one of the most popular edible seeds in the world. You can eat them as-is or process them further into on-the-shelf products like peanut butter, oil, snacks, and soups. Depending on what you want to make, some peanut manufacturing processes include roasting, frying, boiling, grinding, pressing, and coating the peanuts.

Peanuts

If you want to pack into gusseted and pillow style bags and packing speed is important for your packaging process, a continuous bagger with twin sealing jaws could be a good investment.


<h2>The world’s fastest vertical form fill sealing machine</h2>
The VikingMašek Continuous motion bag maker velocity is capable of high speed production up to 300 bpm. The unique center mounted filling tube and natural counterbalanced sealing profiles are designed to provide vibration free, extremely smooth operation at all speeds.

The Velocity is also extremely versatile, handling package sizes up to 300 mm wide and multiple package styles. Patented, independently phased, twin sealing jaws separate the velocity from all other high speed machines and virtually eliminate lost cycle time. This is the world´s fastest bagging machine on the market that has no competition.

Continuous bagger with twin sealing jaws

Sealing small quantities of solids or liquids into plastic bags, requires flexibility of operation.


<h2>Form, fill and seal plastic bags up to 10 kg</h2>
Paglierani's VT 400 VFFS series constructs plastic bags from reels of plastic film, simultaneously filling the bags with product and sealing immediately.

Suitable for dosing and packing solids or liquids by weight from 250 g to 10 kg, it is easy to set up and use. Production is optimised to ensure high technological yield, with easy integration into any production line.

Packaging machine for sealed plastic bags from 250 g to 10 kg

Packaging companies need to pay attention to personalization in shape and design in addition to the attention for the protection of products. The secondary packaging sector faces several challenges to meet customer and marketing demands and regulation standards that come with a large distribution. A good solution in end-of-line packaging is a wraparound case packer that can produce appealing packaging suitable for <em>various</em> configurations.


<h2>Effective wraparound solution for secondary packaging</h2>
The wraparound case packer CPWA from Senzani is a secondary packaging solution. This machine has a production speed of up to 36 cases per minute and can pack a wide range of products such as cartons, tubs, tetra bricks, and bags. Compared to standard case packaging, the wrap-around system ensures solid and firm packaging. In addition, a flat carton wraps the product for protection, providing tighter packaging than a regular box.

In the production process, the operator can easily load horizontal or vertical flat blank magazines with no production cycle interruptions. The picking group takes the flat cases from the magazine, which will then be positioned and folded into a U-shape. Quality control is provided to the folding process of inner and outer flaps, and in the end, the cases are closed with a hot-melt glue application, where during this step, photocells check if the cases are properly closed.

Additionally, changes to adjust for size or format are easily done without any additional tools; this simplifies the use of the machine for the operator.

Wraparound case packer

Some products ask for a plastic reusable lid after the can has been seamed. The closing process might look easy, but often these snap-on lids that need to be on tight, are not placed correctly. And we all know turned caps or caps that fall back to the hopper, will create a jam that you want to prevent.


<h2>Putting on snap-on lids from a sloped conveyor</h2>
The Capper C 127 by Swiss Can Machinery has a sloped conveyor that puts the lids on the tins from such an angle, that improperly placed lids are an exception. The filled and seamed tins are following a path on a conveyor belt. The lids, coming down from a sloped conveyor are put in place on the tin by two rollers, after which the capped tins follow their way to the end of the belt.

The machine can work with different sizes, as long as the tins have a maximum diameter of 127 mm. The side conveyors have two servo drives and are synchronised with the main conveyor.

Capping machine for plastic lid oatmeal tins     

Making sure the right quantity of product is in the packaging can be a precise task if this is not automated. Goods can be sorted and metered, but when it comes to for example tinned peanuts, that doesn’t do the job.


<h2>Automatic filling, weighing and seaming</h2>
The Matic 127 Twin FP by Swiss Can Machinery is a can filling and seaming machine that also automates the weighing of the product. For the filling, the tins are placed on a belt and filled using 20 dosing heads and then weighed using a sensor. The filling station uses a vibrator to make sure the filling of the products is efficient. After filling and weighing, the tins follow their way on the belt to the seaming station where a spindle applies pressure so that the seaming rollers can seam the can in separate stages. The machine can handle different sizes, as long as the tins have a maximum diameter of 127 mm.

Filling and weight checking machine for food cans

Products packed in large bulk bags, such as FIBCs, require vacuum pressure and accurate oxygen or nitrogen content control. Modifying the atmosphere inside the packaging by lowering oxygen levels to 1% or less can protect the products from molds and other microorganisms, as well as insects and rodents, resulting in a prolonged product shelf life.


<h2>Creating an atmosphere with oxygen levels below 1% inside your bulk bags</h2>
The Vacuum and Gas Injection Machine, from Somsix, is a system used to create the optimum atmosphere conditions inside FIBCs or large bags during the packaging of bulk products. The unit allows the operator to create a vacuum and insert the necessary gases in a single cycle to increase productivity. The procedure is done by removing air from a sealed container before injecting essential gases like oxygen, nitrogen, or carbon dioxide into that container. It can also reduce oxygen levels in FIBCs down to 1% or lower in a very short time.

The system has an integrated leak test at the end of each cycle to automatically check for possible leaks in every bag. This feature prevents costly and time-consuming errors. The entire system is built based on food-grade standards guaranteeing hygienic operation.

Vacuum and Gas Injection System for FIBCs

When sealing large bags containing bulk products, a sealer must be reliable to keep the MAP safe in order to avoid products going to waste due to subpar sealing quality. Manual operation for sealing is still very common in the industry, but it is prone to error and inconsistent output. Automating the sealing process can minimize operator error and produce consistently secured sealing.


<h2>Automated complete sealing by single-button operation</h2>
The Automatic Spout Sealer, from Somsix, is a sealing system for large bags used in industrial applications. The system features automated, user-friendly controls where the sealing settings can be preset for a consistent output in every cycle. This method significantly reduces operator error over manual hand-operated sealers. The operator simply positions the spout in the seal mouth and presses one button to execute the sealing process, including the cooling necessary after heating for a complete and secured seal.

Automatic FIBC Sealing machine

Manufacturers requiring big bag packaging have specific sizes, shapes, and material requirements to ensure their products can be handled safely during transportation and storage. However, the FIBC manufacturing process is only sometimes considered sustainable since these big bags are made of polyethylene, which is difficult to recycle. An ideal solution would be working on preventing waste by producing custom-made big bags of the exact right sizes and shapes required by the manufacturer to save on excess offcuts and material costs and minimize production waste.
<h2>Preventing 10-20% of waste by producing big bags in custom shapes, sizes, and material</h2>
Masterpack Group, a leading expert in innovative packaging solutions for bulk materials, designed custom big bag containers used as packaging that provide increased protection, prolong product shelf life, and optimize storage space. FIBCs are available in different shapes, such as circular or U-shape. They can be equipped with specific liner materials like conductive, aluminum, anti-static, dissipative, metalized OPP, or whichever is best for your product. Liners also help protect products from oxygen, moisture, and other possible contaminants while providing safe filling and discharge. The FIBCs are hygienic, and the PE films used as liners are designed and fabricated according to the correct size, not cut to shape from a big tubular PE film. This method minimizes waste in the production of each liner.

Modified Atmosphere Big Bags

Frying is one of the most common preparation methods for nut snacks. Oils bring out distinctive flavors, textures, and aromas, but the absorption percentage in nuts is significantly lower than for other products. For this reason, an efficient system is necessary to achieve an adequate rate of oil turnover in order to maintain the quality of frying oil.


<h2>Increase the frying oil turnover rate while reducing the total volume</h2>
The NU frying plant by Kuipers requires up to 40% less oil volume than conventional systems. Lower oil volume facilitates faster oil turnover time, ensuring better frying oil quality across the production process.

Equipped with an optimized product transportation system, the frying plant efficiently routes nuts and unwanted particles to an advanced paper filtration unit. Besides preventing oil deterioration caused by any nut residue, this method further contributes to lowering overall oil volume.

The NU frying plant integrates into a complete nut processing line with 500 kilograms per hour output capacity.

Frying line for nuts

Kuipers Food Processing Machinery specializes in the technology for the frying and processing of snacks, savouries, nuts, seeds and potato products.

Either coated, battered or enjoyed just as they are, peanuts are popular in different parts of the world as a good companion to a cold beer when watching your favorite series or sports. In the United States, for instance, the consumption of peanuts in 2021 was a record for the second year in a row, with 3,5kg of peanuts consumed by person. To get the best taste and consistency for all these consumers, the advice is to deep fry the nuts. While we all know that too many fried products can be bad for our health, we dare you to find someone who resists the charms of a well-fried peanut. But why is it so popular and how can you make even better peanuts?
<h2>Making peanuts: deep-frying for a safe and tasty product</h2>
Peanuts have a low oil absorption, and this can make their production challenging. Maintaining an efficient industrial frying process, however, helps snack manufacturers achieve the right taste of the nut. Frying is also a quick and effective way of removing moisture for prolonged shelf life. Moreover, some studies suggest that heat treatment decreases levels of aflatoxins, which can harm human health. Ideally, the frying occurs with the oil from the nut being used. But as the investment in peanut oil can be expensive, producers opt for alternatives. Sunflower oil is the most common one.

To make peanuts more efficiently, regardless of the oil type you use, mind how you use it. Using a lower amount of oil and keeping it clean for longer periods helps optimize costs of ingredients, while also controlling the amount of Free Fatty Acids of the nuts – which in general cannot surpass 2%. FFAs are lipid species that contribute to insulin resistance and a higher risk of cardiovascular diseases. A smaller amount of them helps make a healthier product.
<h2>Keeping the oil good: how to maintain oil quality and save frying costs</h2>
Linked to the amount of oil is the turnover time. This is the rate at which the total frying oil volume is refreshed within the system. The shorter the turnover time, the better - it helps prevent the oil degradation and increases product shelf life. It also ensures that you’ll deep fry the peanuts with good quality oil, which you won’t need to change often. Changing oil means stopping production, which takes time, energy, and resources. “When frying peanuts, make sure that the oil you use is good for as long as possible. This way you can significantly reduce your costs”, highlights Valeria Lucinschi, Head of Sales and Business Development at <a href="https://kuipers.nu/">Kuipers</a>.

“With an innovative fryer design you can decrease by up to 40% the total volume of oil used within the system. This combined with an efficient filtration system and temperature control will help you achieve better turnover times - around one-third shorter than usual”, she explains. To produce nuts in a better and more cost-efficient way, make sure your oil turnover rate is low and guarantee its quality throughout the process. Mind the standards of FFAs while still providing the unmistakable taste and feel of the product.

Cracking the code of fried peanuts: how to produce the tasty snack

A fresh salad with a walnut oil dressing or a peanut butter sandwich? A bag of roasted cashews or a pack of almond cookies? The common thread among these tasty treats is nut processing equipment. Not all nut ingredients are indeed nuts, botanically speaking. But the machinery that transforms shelled fruits, legumes, and drupes into fried snacks or a paste is similar. As for the food products, there is a nut recipe for every mood and occasion.

Nuts

Find production technology for Peanuts packing, and connect directly with leading machine manufacturers worldwide

Peanuts packing

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