New Flow Wrapper Caters to Baked-Goods Packagers

A new flow wrapper from BW Flexible Systems, the hand-fed Hayssen R300, is designed to boost uptime, simplify changeover, and minimize cleaning time for food and non-food packaging.

The machine is ideal for foods such as cookies, brownies, croissants, and other sticky or crumbly baked goods, including products in trays. It offers ease of use, guided changeover through the human-machine interface (HMI), and automated jam recovery, with speeds up to 150 packages per minute (ppm).

The new Hayssen R300 Flow Wrapper. Image: BW Flexible Systems

An intuitive HMI.

A key differentiator of the Hayssen R300 flow wrapper is its intuitive, user-friendly HMI that enables new operators to learn the system quickly.

“Our system features a Weintek/Allen-Bradley PLC, enabling operators to seamlessly operate, set up, or troubleshoot machinery. Within the setup screen, we have isolated all components utilized on a shipped basis,” says Brantley Turner, global product line leader at BW Flexible Systems.

“This allows operators to make adjustments directly on the screen without the need to interrupt machine operation, enhancing efficiency and minimizing downtime,” Turner adds. “For instance, operators can modify settings while the machine is actively running, ensuring smooth transitions and uninterrupted recipe execution even when product or film changes occur.”

The flow wrapper also features HMI-guided changeover. This feature simplifies the adjustment of mechanical elements such as folding-box width, height, approach angles, roller positions, jaw height, and temperatures.

“By providing step-by-step guidance through the HMI, we reduce errors and save time during product changeovers, promoting rapid onboarding and confirming manual changes on recipe loads,” Turner says.

He adds that operators commonly overlook adjustments such as approach roller and jaw height post-changeover, leading to production issues. The guided changeover system addresses this challenge, ensuring that all necessary adjustments are made correctly and promptly, thus optimizing production quality and efficiency.

The machine’s adjustable folding box offers operational flexibility, accommodating a range of stock-keeping units (SKUs). The folding box supports three width ranges: 65-130 mm, 95-190 mm, and 125-250 mm.

Clear guards, task lighting, and an open design ease visibility. Image: BW Flexible Systems

Easy to load and clean.

An ergonomic feature of the Hayssen R300 is its ultra-low roll-loading bar height, which aids operator accessibility and enhances both safety and ease of use.

The unwind height is 54.5 in, which is five inches lower than that of other flow wrappers in the same class, Turner says. For operators, the low roll height decreases the risk of lifting injuries and makes film loading easier.

The stainless steel machine is designed for easy cleaning, with sloped pans under the infeed that allow debris to fall through and an open-channel infeed design that simplifies wipe-down and rinsing.

In addition, operators can easily remove the tool-less infeed guards to gain access to the flow wrapper for cleaning. The machine is fitted with hangers to hold side guides during chain cleaning, and the reversible infeed side guides fit into commercial dishwashers.

An integrated, programmable blower cleans debris from the chain. The blower “system can be programmed to activate intermittently as needed, providing flexibility in its operation duration. This feature allows us to tailor the blowing duration according to specific requirements, optimizing cleaning efficiency,” Turner says.

The blower operates during production cycles, contributing to a cleaner environment and higher product quality. The targeted blower is particularly helpful when wrapping crumbly and flaky products, removing debris, and minimizing residue build-up on the chain.

Automated jam recovery.

An automatic jam-recovery feature on the flow wrapper helps maximize uptime and prevent film waste. A servo-motor jaw drive detects and clears product jams without stopping production; the machine’s jaws automatically reopen if they close on a product.

“In case of a jaw jam, indicated by a red light, the system is designed to cut the film, remove any obstruction, close back up, and pull empty bags through before restarting,” Turner says. “The jaws maintain a 180-degree position, facilitating the clearance of two bag cycles without halting production.”

Product jams commonly occur because of misfeeds, improper setup, or oversized products. “Our system is engineered to handle these scenarios effectively, minimizing downtime and maximizing throughput. Many machines in this class typically utilize stepper motors and lack the automated jam-clearing functionality provided by a servo-driven system like ours,” Turner adds.

To enhance product safety and quality control, the flow wrapper features metal-detectable lugs that can be detected with x-ray inspection equipment located downstream. If a lug should detach and become trapped in a bag, it would be identified by metal detectors located on the takeaway conveyors.

Additionally, the machine has clear guards, task lighting, and an open design to provide visibility during operation. An additional control panel at the operator’s point of use and large LED lights that show the system’s status at a distance help operators respond to problems quickly.

The flow wrapper’s RFID login system prevents accidental changes to system operation. The technology eliminates passwords, ensuring that only authorized personnel can modify machine inputs.

RFID login enhances both security and efficiency, reducing downtime from password resets and minimizing errors associated with multiple users. This improves process consistency and accountability, while also streamlining operations.

With its many features for easy use and cleaning, the Hayssen R300 flow wrapper simplifies operations, boosts uptime, and offers manufacturers flexibility for their current and future packaging needs.