Products requiring very deep thermoforming: Packaging OP sets economically

Wolfertschwenden, 22 October 2013 - With the R 900 machine MULTIVAC is launching onto the market a new model of its thermoforming packaging machines, which is particularly suited to large products requiring an extremely deep pack cavity. The R 900 was developed as part of a customer project with a manufacturer of medical products, who packs multicomponent systems for the operating theatre on it.

The OP sets, which are packed on the new R 900 from MULTIVAC, consist of ready-to-use components such as syringes, scalpels, clamps, suture material etc, which are put together based on the individual surgical requirements. These multi-component systems are first packed in a plastic box or a flexible pack, and then wrapped in sterile OP drapes.

"So that the complete set, which is up to 15 centimetres high and often consists of 2 or 3 layers, can be packed automatically on a high-output thermoforming packaging machine, we have developed a new machine concept, which enables a thermoforming depth of 450 mm to be achieved. The machine frame height is consequently 1300 millim-tres. With the first customer machine it is therefore possible to form and seal large packs in a width range of 200 to 600 millimetres, up to 430 millimetres in length and up to 450 millimetres in depth", says Natalie Schmid, Product Manager at MULTIVAC.

The use of the new thermoforming packaging machine, which was developed in close cooperation with the user, brings significant benefits to this supplier of medical technology. The products were previously packed in special film pouches. This meant that there were frequently faults in the packs, since creases formed in the pouch neck during sealing. Thanks to the new thermoforming technology, the number of faulty packs can now be reduced. The loading of the products into the pack can also now be automated. The products are loaded into the pack cavities with several robots.

Special film unwinds for lower web and Tyvek® strip

Flexible films (mono PE) with a thickness of approx. 600μ are used for the packaging films. A thermoforming ratio of up to 14 can be achieved with the new machine design. The R 900 is equipped with a jumbo film unwind. MULTIVAC has integrated a separate film unwind and a separate pre-sealing station in the packaging machine for the Tyvek® strip, through which the OP kit is subsequently sterilised.

The forming station of the R 900 is equipped with a new lifting unit with servo drive, and also with a trapezoidal spindle for the forming plug, which optimises the forming of the pack cavities. The system for explosive forming has also been adapted, in order to be able to provide the large volumes of air required for the big pack cavity.

The sealing die and cutting unit of the R 900 also have new servo lifting units, which are particularly energy-efficient and which generate a closing force of three tonnes. MULTIVAC has also integrated a new common air discharge for the forming system.

The support system with roller conveyor and discharge conveyor can be adjusted in height by means of servo motors. The type of QRP cross cutter developed for special materials has been integrated in the machine.

Due to the machine height of 1.30 metres, MULTIVAC has equipped the machine with a special lifting trolley of the HW 201 type. The doors in the area of the lifting units can also be opened more easily thanks to a special type of side panel. In addition to this, a special safety concept has been developed with sliding guards at hazard points in the loading area and outfeed.