The Gavi Coffee Company was established in Cuba in 1870 by the Gavi榓 brothers. In 1960, their family moved to Los Angeles. F. Gavi & Sons reopened in 1967 and relocated in 2002 to a new 240,000-square-foot site in Vernon, Los Angeles. The goal of this new plant is to have 24 packaging lines, including 12 new production lines, with a total packaging capacity of 100,000 lbs/hr.
The first packaging operation in the new facility was a vacuum packaging line that processed 8.8 and 10 oz. and 1 lb. brick-sized bags of espresso and French roast coffee. For these vacuum packages, microleakage is a matter of great concern to everyone. The microleakage phenomenon is only discovered after binning, and cannot be discovered until the outer package is opened at the store or user.
The resident system can hold 2,500 bags of vacuum-packed coffee,
It can provide a residence time of 45 minutes, so that the microleakage phenomenon will naturally be exposed. There is a leak detector at the exit of the resident system, and acoustic technology is used to detect the leak in the bag.
“The leakage of the bag is manifested after a short period of time after packaging, and it is easy to detect. The problem is that we need to invest in a resident system. This system can leave sufficient time for the product to fully expose the leakage phenomenon. “Leo Fandi, Senior Plant Manager, said, “As a result, we decided to give the product a 45-minute stay. Another problem is that the resident system has to use a certain floor space. The American Fres-co System Company () is our bagging machine. The supplier, a representative of the company, suggested that we contact MultiFlex () so that we installed the MultiFlex Alpine resident system in December 2003."
The system consists of two Alpine reserving towers: one for conveying the bags up and the other for sending the bags back to the ground with a 20-foot cross-belt between the two towers. The conveyor belt provides a convenient traffic path between the two towers for easy maintenance from the four-face system. Each tower has a 650-foot conveyor belt and is divided into 10 layers. A total of 2,500 bags can be stored for a stay of 45 minutes.
Each tower is driven by a variable speed drive. Sensors are installed along the important points of the conveyor belt to make the production process speed moderate, so that the upstream and downstream clogging phenomena have a buffer. Although each tower only occupies 60 square feet of floor space, the vertical FIFO system design provides tremendous cumulative capacity. Fandi said, “The MultiFlex resident system worked very well. Before the system was installed, 3% of the leak bags were not detected. Now it is less than 0.25%.â€
The robot arm on the forming/filling/sealing device picks up four bags at a time and places them on the unloading conveyor.
To further intensify operations and reduce the number of missed inspections, Gavi榓 is installing a Taptone () 500 leak detector that uses acoustic technology to detect vacuum losses in the bags. The working principle of the sensor is to use a wide electromagnetic pulse to stimulate the wall of the package and apply a gentle impact force on the bag. The material vibrates at its natural frequency according to the degree of internal vacuum. The synthesized tone signal is amplified by a loudspeaker, digitally sampled and stored in memory for processing. The digital signal processor generates a real-time signal spectrum and calculates the synthesized frequency of the packaged tone. Then, the frequency is compared with a user-set limit, and those containers whose frequency response exceeds the limit will be judged to be unacceptable.
The system has an operator interface equipped with a menu-driven keypad. Using this keyboard, the operator can formulate inspection criteria based on the shape of the container. The system can also provide real-time detection histograms on the screen. The automatic tracking system monitors and adjusts the limits of nonconforming products based on current production trends.
Fandi said, “The MultiFlex resident system works very well. Before the system was installed, 3% of the leak bags could not be detected. Now it is less than 0.25%.â€
During PD editing visits, the packaging line is processing 10 oz bags at a rate of 72 bags/minute. The film used in these bags is supplied by Fres-Co Systems and consists of the following four layers of adhesive composite (from the outside to the inside): Inverted gravure printed 48-ga polyester, 28-ga foil, 60-ga Biaxially stretched nylon and 3-mil linear low density polyethylene in contact with the product.
In the above bagging operation, the film is folded and packaged into a flat bottom tube, and then the bag is cut open. After filling and compaction, the bag is placed on a rotating carousel.
The conveyor belt transports the bag to the pumping station. After pumping the bag, the bag is sealed and trimmed, and then sent to the belt on the right side of the resident system.
Recently, the company refurbished the Fres-co system's GL 40/4 horizontal forming/filling/sealing equipment, and these bags are run on this system. During operation, the film comes out of a roll mounted on the back of the device and is folded into a tube. After the seal is formed, a flat-bottomed bag is formed. The bag is then cut open and then opened by a vacuum cup and falls into the upright space installed in the conveyor belt. 10 weeks/minutes work intermittently.
The conveyor belt transports the bags underneath the two screw fillers and fills both bags one at a time during the conveyor stop time. Then, the bags continue to advance and the coffee in the bag is compacted by two plungers. Afterwards, the bags turned 90 degrees and fell into the chamber of the rotating carousel at a speed of 4 bags at a time. After the second row of bags was dropped, there were two rows of bags on the carousel and they were rotated 90 degrees. Here, the bag is lifted to the vacuum port for pumping, making the bag a rigid brick-like package. The carousel is rotated 90 degrees again, the bag is raised and the excess material at the top is trimmed. Afterwards, the carousel is rotated 90 degrees further to reach the final packing point. Here, the robot arm picks up four bags at a time and places it on a conveyor belt that carries the bags to the MultiFlex resident system.
The resident system described above consists of two towers, each comprising a 650-foot conveyor belt, but occupying only 60 square feet of floor space. (Note: The diagrams are different from the actual installation. In fact, the two towers are side by side.)
Vertical Form Fill Sealing Machines Process 280 Per Minute
Pouch of coffee, 4 sacks at a time. After being filled and sealed, the pouches are counted and boxed.
When each box filled with 160 bags automatically change.
The latest packing line in the new Gavi & Sons plant is a vertical filling and sealing machine produced in Italy. The agent in the United States is Fres-co Systems, USA. This packing line is McDonald's production of 2.25 ounces of pouch coffee. This machine processes 4 sachets at a time and operates at a speed of 70 cycles/minute. The total output is 280 pouches/min. The film used was also supplied by Fres-co, a two-layer flexible printing material consisting of 48-ga metallized polyester and layered into 2-mil linear low density polyethylene. The film has a patented layer that is glued together with PE to enhance the sealing effect because the continuous motion machine has only a short residence time.
The 1,040 mm (40.9 in) wide film roll is mounted on the back of the machine and is divided into two by a cutter, then passed on both sides of the machine and then cut by a rotating knife into four 130 mm (5.2 in) parallels Article. These parallel strips are brought together to the vertical forming part of the machine. The film was moved downwards through five consecutive drum heaters and the outer edges were sealed and the three internal vertical seals between the pouches were sealed.
A row of 4 screw fillers are installed below the funnel to fill the ground coffee. A vibrating rod compacts the product during filling. This will allow the pouch to be filled into the top seal. According to Fres-co, this has resulted in a material reduction of approximately 15% compared to other vertical form-fill sealing machines.
The top seal of the filled pouch is performed at the same time as the bottom seal of the next unfilled pouch, and is accomplished by a rotating horizontal seal rod. These seals have cutters that cut a gap in the pouch's vertical seal to facilitate tearing. Rotate the horizontal cutter to cut the pouch horizontally.
Then, the pouches fall onto the conveyor belt and are distributed and packed by conveyor belts. For every 40 revolutions of the machine, 160 sachets are loaded into the box, the conveyor belt is activated, the filled box is removed and an empty box is replaced. The box was molded by a 215-type box spreader provided by Marq Packaging Systems (). The device uses a double thread lifting system to ensure that the box remains in shape during tape application.
The first packaging operation in the new facility was a vacuum packaging line that processed 8.8 and 10 oz. and 1 lb. brick-sized bags of espresso and French roast coffee. For these vacuum packages, microleakage is a matter of great concern to everyone. The microleakage phenomenon is only discovered after binning, and cannot be discovered until the outer package is opened at the store or user.
The resident system can hold 2,500 bags of vacuum-packed coffee,
It can provide a residence time of 45 minutes, so that the microleakage phenomenon will naturally be exposed. There is a leak detector at the exit of the resident system, and acoustic technology is used to detect the leak in the bag.
“The leakage of the bag is manifested after a short period of time after packaging, and it is easy to detect. The problem is that we need to invest in a resident system. This system can leave sufficient time for the product to fully expose the leakage phenomenon. “Leo Fandi, Senior Plant Manager, said, “As a result, we decided to give the product a 45-minute stay. Another problem is that the resident system has to use a certain floor space. The American Fres-co System Company () is our bagging machine. The supplier, a representative of the company, suggested that we contact MultiFlex () so that we installed the MultiFlex Alpine resident system in December 2003."
The system consists of two Alpine reserving towers: one for conveying the bags up and the other for sending the bags back to the ground with a 20-foot cross-belt between the two towers. The conveyor belt provides a convenient traffic path between the two towers for easy maintenance from the four-face system. Each tower has a 650-foot conveyor belt and is divided into 10 layers. A total of 2,500 bags can be stored for a stay of 45 minutes.
Each tower is driven by a variable speed drive. Sensors are installed along the important points of the conveyor belt to make the production process speed moderate, so that the upstream and downstream clogging phenomena have a buffer. Although each tower only occupies 60 square feet of floor space, the vertical FIFO system design provides tremendous cumulative capacity. Fandi said, “The MultiFlex resident system worked very well. Before the system was installed, 3% of the leak bags were not detected. Now it is less than 0.25%.â€
The robot arm on the forming/filling/sealing device picks up four bags at a time and places them on the unloading conveyor.
To further intensify operations and reduce the number of missed inspections, Gavi榓 is installing a Taptone () 500 leak detector that uses acoustic technology to detect vacuum losses in the bags. The working principle of the sensor is to use a wide electromagnetic pulse to stimulate the wall of the package and apply a gentle impact force on the bag. The material vibrates at its natural frequency according to the degree of internal vacuum. The synthesized tone signal is amplified by a loudspeaker, digitally sampled and stored in memory for processing. The digital signal processor generates a real-time signal spectrum and calculates the synthesized frequency of the packaged tone. Then, the frequency is compared with a user-set limit, and those containers whose frequency response exceeds the limit will be judged to be unacceptable.
The system has an operator interface equipped with a menu-driven keypad. Using this keyboard, the operator can formulate inspection criteria based on the shape of the container. The system can also provide real-time detection histograms on the screen. The automatic tracking system monitors and adjusts the limits of nonconforming products based on current production trends.
Fandi said, “The MultiFlex resident system works very well. Before the system was installed, 3% of the leak bags could not be detected. Now it is less than 0.25%.â€
During PD editing visits, the packaging line is processing 10 oz bags at a rate of 72 bags/minute. The film used in these bags is supplied by Fres-Co Systems and consists of the following four layers of adhesive composite (from the outside to the inside): Inverted gravure printed 48-ga polyester, 28-ga foil, 60-ga Biaxially stretched nylon and 3-mil linear low density polyethylene in contact with the product.
In the above bagging operation, the film is folded and packaged into a flat bottom tube, and then the bag is cut open. After filling and compaction, the bag is placed on a rotating carousel.
The conveyor belt transports the bag to the pumping station. After pumping the bag, the bag is sealed and trimmed, and then sent to the belt on the right side of the resident system.
Recently, the company refurbished the Fres-co system's GL 40/4 horizontal forming/filling/sealing equipment, and these bags are run on this system. During operation, the film comes out of a roll mounted on the back of the device and is folded into a tube. After the seal is formed, a flat-bottomed bag is formed. The bag is then cut open and then opened by a vacuum cup and falls into the upright space installed in the conveyor belt. 10 weeks/minutes work intermittently.
The conveyor belt transports the bags underneath the two screw fillers and fills both bags one at a time during the conveyor stop time. Then, the bags continue to advance and the coffee in the bag is compacted by two plungers. Afterwards, the bags turned 90 degrees and fell into the chamber of the rotating carousel at a speed of 4 bags at a time. After the second row of bags was dropped, there were two rows of bags on the carousel and they were rotated 90 degrees. Here, the bag is lifted to the vacuum port for pumping, making the bag a rigid brick-like package. The carousel is rotated 90 degrees again, the bag is raised and the excess material at the top is trimmed. Afterwards, the carousel is rotated 90 degrees further to reach the final packing point. Here, the robot arm picks up four bags at a time and places it on a conveyor belt that carries the bags to the MultiFlex resident system.
The resident system described above consists of two towers, each comprising a 650-foot conveyor belt, but occupying only 60 square feet of floor space. (Note: The diagrams are different from the actual installation. In fact, the two towers are side by side.)
Vertical Form Fill Sealing Machines Process 280 Per Minute
Pouch of coffee, 4 sacks at a time. After being filled and sealed, the pouches are counted and boxed.
When each box filled with 160 bags automatically change.
The latest packing line in the new Gavi & Sons plant is a vertical filling and sealing machine produced in Italy. The agent in the United States is Fres-co Systems, USA. This packing line is McDonald's production of 2.25 ounces of pouch coffee. This machine processes 4 sachets at a time and operates at a speed of 70 cycles/minute. The total output is 280 pouches/min. The film used was also supplied by Fres-co, a two-layer flexible printing material consisting of 48-ga metallized polyester and layered into 2-mil linear low density polyethylene. The film has a patented layer that is glued together with PE to enhance the sealing effect because the continuous motion machine has only a short residence time.
The 1,040 mm (40.9 in) wide film roll is mounted on the back of the machine and is divided into two by a cutter, then passed on both sides of the machine and then cut by a rotating knife into four 130 mm (5.2 in) parallels Article. These parallel strips are brought together to the vertical forming part of the machine. The film was moved downwards through five consecutive drum heaters and the outer edges were sealed and the three internal vertical seals between the pouches were sealed.
A row of 4 screw fillers are installed below the funnel to fill the ground coffee. A vibrating rod compacts the product during filling. This will allow the pouch to be filled into the top seal. According to Fres-co, this has resulted in a material reduction of approximately 15% compared to other vertical form-fill sealing machines.
The top seal of the filled pouch is performed at the same time as the bottom seal of the next unfilled pouch, and is accomplished by a rotating horizontal seal rod. These seals have cutters that cut a gap in the pouch's vertical seal to facilitate tearing. Rotate the horizontal cutter to cut the pouch horizontally.
Then, the pouches fall onto the conveyor belt and are distributed and packed by conveyor belts. For every 40 revolutions of the machine, 160 sachets are loaded into the box, the conveyor belt is activated, the filled box is removed and an empty box is replaced. The box was molded by a 215-type box spreader provided by Marq Packaging Systems (). The device uses a double thread lifting system to ensure that the box remains in shape during tape application.
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