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Packaging machines designed to meet the special requirements in the panels industry.

Packaging panels of expanded polystyrene used to be a problem: after wrapping the film around the product the heat in the shrink tunnel would cause the surface of the panels to wrinkle.  Mac Due realized that packaging with two-reel machines required more heat for shrink wrapping as compared to packaging with machines featuring a tie-shaped wrapping system. Mac Due took on the challenge and was the first company to design a machine with tie-shaped wrapping system large enough to package panels.

Another interesting solution is the use of “Leister” units instead of shrink tunnel. In situations where “extreme” shrinking was not required, shrinking the film on the sides of the package with the use of these powerful industrial blow dryers was considered sufficient. During the shrinking process the heated air contained in the package would create air pockets, preventing the hot film from coming into contact with the polystyrene until the film was cooled.

 

Competing manufacturers built tie-shaped wrapping systems for panels, however the “ties” were so large that they encountered problems with the sliding of the film. These companies applied rollers to aid the insertion of the panels into the “tie” but this resulted in the disbanding of the stacks of products with some lightweight panels.  MacDue met the problem by substituting the rollers with a mechanical pusher installed below. The solution guaranteed insertion into the tie-shaped wrapping system without disbanding the bundle, and allowed the machine to handle shorter products.

 

In 2005, Mac Due patented a new Centre-folding unit, to install in machines with tie-shaped wrapping systems. This was in response to difficulties in managing a very heavy centre-folded film reel in such large machines.  Mac Due came up with an innovative solution that enabled the use of two reels of simple film, resulting in facilitated reel handling, doubling of the machine’s autonomy, and easier printing on film.

Complete turnkey lines for packaging tissue, highly specialized automated machines for tissue products and solutions to all requirements in this sector.

Constructing machines for packaging tissue doesn’t solve the problem for the customer: the real solution is placing the machines into a line with a full understanding of the needs of this sector.  For this reason, Mac Due has undertaken efforts in the Tissue segment to develop solutions that go beyond packaging, including up-enders, dividers, adding units, special feeding systems according to product, stackers, etc.

Mac Due also places great attention on the handling of the product along the entire line with conveyor belts controlled by inverters. All storing and accumulating systems are programmed and managed by an electrical cabinet and are extremely important for optimising the production and output of each machine.

The first steps in this segment were made in Lucca, known as the Tissue capital.  Working from a list of the problems inherent to this sector, we gradually identified specific solutions; for instance, in the packaging of industrial single rolls we used the classic two-reel machines because the market demanded only wrapping suited for transport in polyethylene.  In 2000, things started to change: the single roll began to appear in supermarkets, requiring a more practical wrapping for transport as well as a primary wrapping to enhance the product’s impact on the shelf.

Mac Due immediately took on the challenge and came up with the Minisac 50, a machine that enabled the primary wrapping to be in polyethylene or polypropylene and sealed on all sides with a continuous lateral sealer.

This machine has had great success in Italy and in other countries and has developed mechanically to meet the demands for higher speeds. The latest model in fact has four brushless motors and mobile carriage for the cross sealer.

For wrapping bundles for transport, the technique went from packaging having side film clots, using the two-reel machines, to 100% sealing using Mac Due machines with the tie-shaped wrapping system.To increase the speed of these latter machines, the technique evolved from the system of introducing the pack by means of a pusher to the system of in-line motorized conveyors.

Mac Due has also constructed a range of highly flexible, extremely efficient case packers with feeding dedicated to each product handling up to 220 single rolls. With regard to the palletization of finished products, the common approach was to use anthropomorphic robots (with multiple grippers able to serve up to three lines) flanked by stretch wrapping stations.  However, the robots were constrained by a speed limit of 10-12 operations per minute. In order to increase speed Mac Due designed a new palletizer called PalWrap featuring Cartesian axes which prepared and gripped a whole layer of products and palletized it directly on the stretch wrapping station.  In a first for the sector, this solution also allowed single rolls to be automatically palletized (each layer is immediately wrapped, thereby preventing the single rolls from falling or disbanding).  Furthermore, Mac Due has implemented in the PalWrap system the top placing unit, cover placing unit and the double pallet in response to customer demands.