Horizontal flow packaging · Silver with Carton Feeder
Silver Model Horizontal Flow Wrapper with Carton Feeder
A servo flow wrapper that sets a card or tray under every pack, so soft, filled and cup-shaped products travel flat, stay in shape and look their best on the shelf.
Silver Model Horizontal Flow Wrapper with automatic carton feeder and soft-contact in-line feeding.
120 /min
packs, 2 cups on a card, cold-seal film
180 /min
products into the pack at full speed
1 card
per pack from an automatic magazine
Hot + cold
seal on one machine, Omron servo control
Overview
About the Silver with Carton Feeder
Some products should not lie loose in a film. A chocolate truffle cup, a muffin or a slice of cake needs a firm base: it keeps the pack flat, stops the products from sliding into each other and gives the shopper a clean, premium look. The Silver Model with Carton Feeder adds exactly this step to the proven Silver servo wrapper. A card magazine releases one precut card per pack into the lug chain, the soft-contact infeed lays the products on it, and the wrapper closes card and product together in one pillow pack. Card, chain, film and jaws run on one Omron motion controller, so a missing product never produces an empty card or an empty pack.
What a Carton Feeder Adds to a Flow Wrapper
In a carton-fed flow pack the product rests on a thin board, a U-shaped card or a shallow tray inside the film. The card carries the weight, protects coatings and edges, and lets several pieces be packed side by side without touching. On the Silver the card is fed in-line, at the same pitch as the pusher fingers, so the machine keeps the speed of a standard horizontal flow wrapper (HFFS). Products are separated on servo belts that never press them together, laid on the card, wrapped with a 15 mm fin seal underneath and sealed and cut by rotary jaws.
Working principle: soft-contact product feeding (1 to 4), card feeding (5, 6) and film forming, sealing and discharge (7, 8).
Complete line: soft-contact belts, carton feeder and Silver wrapper on one frame.
Why Choose the Silver with Carton Feeder
Product protection. Cups, coatings, fillings and soft sponges sit on a firm base and never rub against each other in the pack.
Premium shelf look. Flat, square packs with a visible product on a kraft, white, gold or black card.
No product, no card. Sensors and the motion controller skip the card and the pack when a product is missing.
Flexible. Card feeding switches off by recipe, and the machine then runs as a standard Silver flow wrapper.
Hygiene. Drives sit behind the frame. Guards and product-contact parts are AISI 304; belts and plates come off without tools.
Applications
Silver Model Horizontal Flow Wrapper with Carton Feeder: Application Areas
Chocolate, confectionery and bakery products that need a firm base in the pack, from truffle cups to cake slices.
The carton feeder is the right choice whenever a product is soft, filled, cup-shaped or packed in pairs and should arrive at the shelf exactly as it left the line. The truffle cups below were packed on this machine: two square milk-chocolate cups of 40 × 40 × 15 mm on a kraft card, in a clear cold-seal flow pack, at 150 to 200 packs per minute. Protrus matches the card, film, seal type and pusher fingers to each product and proves them in a trial with the customer’s own product and packaging. The packing room should be held at 18 to 20 °C (64 to 68 °F) so chocolate stays firm and products do not take up moisture.
Truffle cup, 40 × 40 × 15 mm
Two cups on a kraft card
Finished clear flow pack
Made on the Silver with Carton Feeder: Chocolate Truffle Cups
More Products on a Card or Tray
Pralines on tray
Brownies on card
Macarons on tray
Mini cheesecakes
Muffins on card
Cupcakes on card
Roll cake slices
Layer cake slice
Card and Tray Formats
| Base | Typical products | Recommended film | Seal |
|---|---|---|---|
| Flat precut card (kraft, white, gold) | Truffle cups, brownies, mini cheesecakes, muffins, cupcakes | Clear or printed OPP, pearlized OPP | Cold seal for chocolate, hot seal for bakery |
| Gold or black board | Cake slices, roll cake, premium pralines | Clear OPP for full product view | Hot or cold seal |
| Shallow paper or plastic tray | Pralines, macarons, small cakes in rows | Metallized or printed OPP | Cold seal for coated products |
| Card with several products | Gift and multi packs of 2 to 4 pieces | Printed OPP or mono-PP | Hot or cold seal |
Soft-Contact Feeding and Automatic Carton Feeder
Products leave the cooling tunnel in a steady, aligned flow. A 90° feeding conveyor turns them into the wrapper axis and the soft-contact in- line feeding system takes over: servo vacuum belts, each a little faster than the one before, open a clean gap between the products, and photocells check position and spacing on every belt. Misplaced or broken pieces are blown off by a short air blast without slowing the line, and an optional turning unit rotates products by 90° on two belts running at different speeds. The carton feeder takes precut cards from an inclined magazine that can be topped up while the machine runs and sets one card at each pusher pitch; the products are laid on it just before the film forming box.
Output for 2 truffle cups of 40 × 40 × 15 mm per card, 20 µm OPP + 20 µm pearlized OPP cold-seal film. Final figures depend on product, card and film and are confirmed after a trial.
Specifications
Silver Model Horizontal Flow Wrapper with Carton Feeder: Technical Specifications
Key data for the standard machine. Final values depend on the product, the card and the film and are confirmed in each Protrus offer.
Technical Data
| Parameter | Silver Model with Carton Feeder | Note |
|---|---|---|
| Machine type | Servo horizontal flow wrapper (HFFS) with automatic carton feeder | Pillow pack, fin seal under |
| Output with card | 120 to 200 packs/min | Cold-seal film |
| Output without card | Up to 400 packs/min cold seal; up to 200 packs/min heat seal | Card feeder off |
| Carton feeder | Inclined magazine, servo-synchronized, one card or tray per pusher pitch | Refill while running |
| Product infeed | Soft-contact: 4 servo vacuum belts, photocells, side guides, air-blast reject | 90° turning optional |
| Film reel | Width up to 280 mm (11 in), diameter max. 350 mm (11.8 in), core 70 to 76 mm | Two spindles |
| Film handling | Automatic reel transfer without stopping, mechanical centering, dancer arm | |
| Packaging films | OPP, BOPP, CPP, pearlized and metallized OPP | Ref. 20 + 20 µm OPP |
| Sealing | Hot and cold seal; 3 fin seal disc sets (4 for heat seal), seal width 15 mm | Each set on own drive |
| End-seal jaws | Single-motor alloy jaws, 1.75 mm profile; straight or zigzag HSS cobalt blades | Open at standstill |
| Registration | Digital cut length, servo-set print-mark sensor, automatic ± correction | |
| Chain conveyor | Product-specific pushers, AISI 304 top plates and guides, mechanical tensioning | Double-product stop |
| Control | Omron PLC and motion control, up to 10 servo axes, 10 in touch HMI, recipes | Remote access |
| Components | Sick, SMC, Siemens/Schneider, Tramec gearboxes, SKF/FAG bearings | Sealed cabinet |
| Electrical supply | 400 V/50 Hz, 460 V/60 Hz, 220 V/60 Hz; 3 phase; wrapper approx. 7 kW | 60 Hz on request |
| Compressed air | 6 bar (87 psi), dry and oil-free | |
| Weight | Approx. 3,500 kg (7,700 lbs) with carton feeder and in-line feeding | Depends on layout |
| Dimensions | Typical line approx. 8,750 × 1,050 × 1,650 mm (L × W × H) | To factory plan |
| Construction | Aluminum plates on steel frame; guards and product-contact parts AISI 304 | Date coder input |
Carton feeder with card magazine, and twin film reels with automatic reel transfer.
Main Assemblies and Options
Carton feeder. The magazine holds a stack of precut cards; each card is separated, squared up in the guide and set on the chain at pusher pitch.
Options. Inkjet or thermal date coder, metal detector, X-ray inspection, checkweigher, water-cooled infeed conveyor and a double- deck pack collection conveyor.
Frequently Asked Questions
Get a Quote
Plan your carton-fed flow pack line with Protrus
We run a trial on your product and return a layout and a budget offer for the Silver Model Horizontal Flow Wrapper with Carton Feeder.
Prefer email? info@protrus.com