Horizontal flow packaging · Silver
Silver Model Horizontal Flow Wrapper
A versatile servo flow wrapper for medium-to-high output: up to 400 pieces per minute on cold-seal film and up to 200 on heat-seal film, with in-line feeding that brings products into the pack without hand contact.
Silver Model Horizontal Flow Wrapper with long in-line servo feeding, double film reels and touch-screen control.
400 /min
maximum output on cold- seal film
200 /min
maximum output on heat- seal film
9 kW
installed power, 400 V/50 Hz, 460 V/60 Hz, 220 V/60 Hz
Up to 10 servo motors
Omron motion control, PLC and 10 in HMI
Overview
About the Silver
The Silver is the all-round model of the Protrus Horizontal Flow Pack Packaging range. Where the Titan is built for maximum speed on cold-seal film, the Silver is built for flexibility: one machine seals both cold-seal and heat-seal films, so a plant can pack chocolate bars in the morning and biscuits, cakes or halva in the afternoon. It handles a wide variety of products with customizable pack ratios and can be joined to any compatible automatic feeding system. Each product is wrapped in a pillow pack with a fin seal underneath and a crimped seal at both ends. Ten Omron servo motors drive the feeding, the lug chain, the bottom sealing discs and the end-seal jaws, and all of them follow one Omron motion controller. Pack length, product pitch and seal timing are stored as a recipe on the 10 in Omron touch screen, which saves time and cost at every product change.
How it works
How a Horizontal Flow Wrapper Packs a Product
In a horizontal flow wrapper (also called a flow pack or HFFS machine) the product moves in a straight line and the pack is formed around it while it moves. Film from a reel runs through a forming box that folds it into a tube; bottom discs pull the tube forward and close it with a lengthwise fin seal; rotating jaws then seal and cut the film between two products. Because nothing stops and restarts, a flow wrapper reaches outputs that bagging or tray machines cannot, which is why it is the standard pack for bars, biscuits and snack cakes.
Silver working principle: product handling (1 to 3), film forming and sealing (4 to 7) and discharge (8).
Silver in an L-shaped line, fed by the ADS automatic distribution conveyor.
Why Silver
Why Choose the Silver Model
Hot and cold seal in one machine. A heated fin-seal disc and heated jaws handle heat-seal films; for chocolate and heat-sensitive products the same machine runs cold-seal film with pressure only.
Servo precision. Cut length is controlled digitally and print-mark registration with automatic correction keeps every cut on the printed mark.
Hands-free infeed. The in-line feeding system brings each product into the pack without direct handling, which improves hygiene and keeps the line running efficiently.
Fewer stops for film. A double reel holder with auto splicer joins the next reel while the machine runs, and mechanical film centering keeps the web in line.
Hygiene and access. Drives sit behind the frame, away from the product, and every surface in contact with the product is AISI 304 stainless steel.
Line-ready. Date coder input included, and synchronized signals for automatic feeding systems, printers, labelers and inspection units.
Applications
Silver Model Horizontal Flow Wrapper: Application Areas
One flow wrapper for chocolate, bars, wafers, sweets, cakes, biscuits and bakery products, in cold-seal or heat- seal film.
The Silver suits plants that run several product families on one packing line. Typical products are bar and tablet chocolate, wafers, protein and cereal bars, sweets, cakes, single biscuits, halva, croissants and buns. Cold seal keeps heat away from chocolate; hot seal suits bakery products and clear films. For every product Protrus selects the film, the seal type, the jaw profile and the infeed module, and checks the result on a trial run with the customer’s own product and film. A packing room at 18 to 20 °C (64 to 68 °F) keeps chocolate firm and stops sugar products from taking up moisture.
Products and Pack Styles for the Silver
Bar chocolate
Tablet chocolate
Wafers
Protein bars
Cereal bars
Sweets
Cakes
Single biscuits
Halva
Croissants
Buns
Product Guide: Pack, Film and Infeed
| Product | Typical pack | Film and seal | Recommended infeed |
|---|---|---|---|
| Bar and tablet chocolate | Single bar or tablet | Cold-seal OPP or BOPP, no heat on the chocolate | Chocolate transfer conveyor from the demoulder |
| Wafers, protein and cereal bars | Single bar or wafer | OPP or BOPP, cold or hot seal | ADS distribution and in-line servo feeding |
| Sweets | Single piece | OPP or BOPP, cold seal | ADS distribution from the cooling tunnel |
| Cakes and single biscuits | Single cake or biscuit | Hot-seal OPP or BOPP | Soft-contact four-stage servo belts |
| Halva | Single pack | Hot-seal OPP or CPP | Soft-contact belts with gentle transfers |
| Croissants and buns | Single pack | Clear CPP or BOPP, hot seal | Soft-contact belts from the cooling conveyor |
Feeding
Feeding Modules Matched to the Line
The ADS automatic feeding system takes products from the cooling tunnel or depositor, aligns each row on a row aligner belt, splits the rows in a distribution station and holds a short buffer in a stock station, so the wrapper always receives products in single file at its own pitch. Belts are food grade and sit on removable AISI 304 plates with scrapers and drip trays; pneumatic belt tracking stops the system if air pressure drops. For fragile cakes and biscuits, a four-stage servo belt conveyor opens a closed row into even gaps, each belt slightly faster than the last. An optional turning unit with two belts at different speeds rotates products by 90° when the pack needs it.
Four-stage servo belt feeding
ADS distribution conveyor
Chocolate transfer conveyor
Guide rail and product sensor
Specifications
Silver Model Horizontal Flow Wrapper: Technical Specifications
Key data for the standard machine. Final values depend on the product, the film and the configuration and are confirmed in each Protrus offer.
Technical Data
| Parameter | Silver Model | Note |
|---|---|---|
| Machine type | Servo-controlled horizontal flow wrapper (HFFS) with in-line feeding, fin seal underneath | Three-seal pillow pack |
| Output, cold-seal film | Up to 400 pcs/min | Depends on product and film |
| Output, heat-seal film | Up to 200 pcs/min | Limited by seal dwell time |
| Pack length / product size | 20 to 400 mm; product width 10 to 85 mm, height 5 to 70 mm | Typical range, other sizes on request |
| Film reel | Max. roll diameter 350 mm (13.8 in), reel core 70 to 76 mm | Double reel holder with auto splicer |
| Film handling | Mechanical film centering; digitally controlled cutting length | Next reel joined while running |
| Packaging films | OPP, CPP and BOPP films | Samples tested by Protrus engineers |
| Sealing | Hot and cold sealing | Cold seal for chocolate |
| Fin seal discs | 3 disc sets: puller, single heater and folding | |
| End-seal jaws | Servo jaw set with straight or zigzag HSS blades | Jaws open automatically at standstill |
| Registration | Digitally controlled cutting length, print-mark registration with automatic correction | |
| Chain conveyor | Product-specific pusher fingers and side guides; mechanical chain tensioning | Double-product detection stops the machine |
| In-line feeding | Products enter the pack without direct handling; works with any compatible automatic feeding system | Modular, can be extended later |
| Control | Omron PLC, motion control, servo drives and inverters; 10 Omron servo motors; 10 in Omron HMI | Recipe per product |
| Components | Siemens and Schneider electrical equipment, DKP control cabinet, ELK AC motors, Tramec (Italy) gearboxes, Omron relay modules, Sick photoelectric sensors, safety limit switches and emergency relays, SMC pneumatics, SKF/FAG/ORS bearings | |
| Electrical supply | 400 V/50 Hz, 460 V/60 Hz, 220 V/60 Hz; 9 kW installed | Depends on configuration |
| Compressed air | 6 bar (87 psi) | Dry, oil-free air |
| Weight | Approx. 3,000 kg (6,600 lb) | Flow pack machine |
| Dimensions | Project-specific, drawn to suit the customer’s factory layout | |
| Construction | Product-contact surfaces AISI 304 stainless steel | Date coder input included |
Main Assemblies and Options
End seal and outfeed.
A perforated stainless hood covers the rotary jaws, lets heat escape and keeps the seal visible; packs leave on a blue food-grade belt.
Dual film reels.
The next reel waits on the double reel holder and the auto splicer joins it on the fly, with guide rollers keeping the web flat.
Options.
Inkjet date coder, metal detector, X-ray, checkweigher, water-cooled conveyor and double- deck collection conveyor.
End-seal guard and outfeed, dual film reels and the complete Silver with in-line feeding.
Frequently Asked Questions
Get a Quote
Find the right flow wrapper with Protrus
We test your product and film, propose the infeed and layout, and return a budget offer for the Silver Model Horizontal Flow Wrapper.
Prefer email? info@protrus.com