As a technical team that has been deeply involved in the field of packaging equipment for 20 years, we think about a question every day: Why can biscuit boxes, medicine blisters, and daily chemical bottle sleeves of different shapes be formed by the same packaging machine? Today, we will take you into the R&D workshop of Ply-Pack to reveal the technical logic behind the film forming of packaging machines.
Step 1: Film pretreatment - the key to making materials "obedient"
The first step in the film forming of packaging machines is to adapt materials such as PET, PE or composite aluminum foil to the rhythm of the equipment. Our factory's equipment will automatically adjust the preheating temperature according to the thickness of the film. For example, the commonly used film of 0.1-0.3mm will be softened and pretreated in the range of 40-60℃. The core of this stage is the film tension control. Through the linkage of the servo motor and the deviation correction device, it is ensured that the material is flat and wrinkle-free when entering the forming station, which is as important as ironing and shaping the cloth.
The precision revolution of heat-sealing forming technology
When the film enters the core forming area, the real magic of packaging machine film forming begins. Our multi-station forming system will simultaneously complete three tasks: precise mold alignment, vacuum adsorption shaping, and instant heat sealing shaping. Taking the production of food trays as an example, the equipment can turn a flat film into a three-dimensional box with a slot within 0.8 seconds. This is due to the self-developed heat-sealing forming technology-through 216 independent temperature control points to adjust the pressure and temperature in real time, which can not only avoid the film from being burned through, but also ensure that the sealing strength meets the standard.
Dynamic compensation: a killer for dealing with complex film materials
Many customers have asked us: "Why do some packaging machines always have edge warping when forming film materials?" This is often because the equipment lacks dynamic compensation capabilities. Our engineers have added AI algorithms to the film tension control module to automatically adjust the traction roller speed and mold gap when the material ductility fluctuations are detected. The production line customized for a chocolate company last year can even process environmentally friendly film materials containing 30% biodegradable ingredients, and the molding qualification rate is stable at more than 99.2%.
From the laboratory to the production line: How we break through the technical bottleneck
The molding of packaging machine film materials seems simple, but in fact it is necessary to balance material properties, equipment precision and production efficiency. Our R&D team was stationed in the customer's factory for three consecutive months and found that traditional equipment needs to manually change molds when switching to special-shaped packaging, which seriously affects production capacity. Now, Ply-Pack's multi-station molding system has achieved "one-click mold change". Through modular mold warehouses and adaptive temperature control modules, the film molding conversion from square boxes to round cans can be completed in 30 minutes, helping customers to cope with small batch customized order needs.
