In the field of nut packaging, melon seeds have long faced technical bottlenecks such as unstable nitrogen filling and sealing and poor adaptability to customized production due to their irregular particle shape and easy breakage. The PLY-PACK R&D team has specifically developed the seventh-generation melon seed packaging machine that integrates dynamic compensation algorithms and flexible production lines to provide the industry with high-precision intelligent packaging equipment solutions.
The core difficulty of the melon seed packaging machine lies in the nitrogen filling and sealing link. Traditional equipment often has insufficient local heat sealing strength or excessive gas residue because it cannot perceive the stacking density of melon seeds in real time. The dynamic compensation algorithm adopted by PLY-PACK constructs a three-dimensional spatial distribution model of melon seeds by integrating laser contour scanning and pressure sensing data. When it is detected that the particle gap in a specific area exceeds 1.2mm, the system automatically triggers a two-level compensation mechanism: first, the vibration plate amplitude is adjusted to optimize the uniformity of the material falling, and then the heat sealing knife pressure value is dynamically corrected at a frequency of 0.05 seconds/time. The production data of a customer in Zhejiang Province shows that this technology reduces the leakage rate of 250g packaging from 1.1% to 0.28%, and the nitrogen purity is stable at more than 99.6%.
In order to meet the market demand for multiple categories and small batches, the PLY-PACK melon seed packaging machine adopts a "building block" flexible production line design. The main body of the equipment consists of standardized basic modules (including racks, transmission systems, and control centers) and replaceable functional modules. Taking the metering system as an example, customers can choose a spiral metering module (for original melon seeds) or a combination weigher module (for mixed nuts) according to the characteristics of the product. More importantly, all modules are equipped with intelligent docking interfaces and support hot-swap replacement. A foundry in Jiangsu Province used this feature to complete the switching and debugging of the two production lines of caramel melon seeds and pecan kernels within 4 hours, and the equipment utilization rate was increased to 91%.
Innovative application of AI visual grading system
In the seventh generation of melon seed packaging machine, PLY-PACK introduced an AI visual system driven by deep learning. The 20-megapixel high-speed camera equipped with the device captures dynamic images of melon seed flow at a rate of 120 frames per second, and identifies large particles or surface crack defects with a diameter deviation of more than 15% through a convolutional neural network. After actual testing, the system's accuracy in judging the integrity of melon seeds reached 98.7%, and the false rejection rate was controlled within 0.8%. A high-end brand in Hunan used this function to independently package the selected premium melon seeds and successfully launched the "Emperor's Grain" series of products with a premium of 28%.
The technological breakthrough of PLY-PACK melon seed packaging machine marks the evolution of intelligent packaging equipment from a single function to a systematic solution. The dynamic compensation algorithm solves the problem of sealing special-shaped particles, the flexible production line reconstructs the production organization logic, and the AI visual system opens up a new dimension of quality grading. With the large-scale application of the equipment in companies such as Qia Qia and Bestore, this technical system is driving the transformation of the melon seed packaging industry from "mechanical replication" to "intelligent innovation". The head of R&D revealed that the next generation of equipment will integrate humidity sensing and bacterial control modules to further expand the application boundaries of intelligent packaging equipment in the field of functional foods.
