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Mueller plant brimming with technology

From laser scanning of cheese blocks to multi-axis servo-controlled case and tray packers, this dairy plant makes automated packaging systems a top priority.

Pw 8772 Mueller Weber1

Situated near Dresden, Germany, in a small town called Leppersdorf, the enormous dairy called Mueller-Plant is filled with enough automated packaging equipment to make even a veteran packaging journalist dizzy. Among the highlights:

 a line for slicing, packaging, and case packing of sliced cheese

 a line for secondary packaging of round cheese pieces into corrugated trays followed by robotic placement of the trays onto pallets.

This story looks at both operations, beginning with the sliced cheese line.

The sliced cheese line begins with a servo-driven automatic slicer from Weber (www.webernet.de) that attains impressive levels of throughput, flexibility, and accuracy thanks to the servo technology on which it’s based. Including infeed, slicing, and discharge stations, a total of 23 servo motors are deployed. All are supplied by Elau (www.elau.com), as is the PacDrive controller that commands the servos.

Cheese is fundamentally difficult to slice and package automatically without sacrificing either throughput or weighing accuracy. This is partly because the roughly 50-lb blocks fed into the slicer are never uniform in dimension or weight. And on top of that, the pattern of holes in, say, Swiss cheese is never uniform.

The Weber system confronts these challenges head on by “deciding” how each block of cheese should be sliced. First, incoming blocks of cheese are scanned by a laser. Software then instantly calculates dimensions and weight and sends this data to the central controller so that the slicer knows how thick the slices need to be in order to get, say, seven slices that weigh 200 g. Also helping to determine slice thickness is a vision system/software combination that takes into account the size of the holes when Swiss cheese is being sliced and sends that data to the controller, too.

Slices drop from the rotary cutting blade onto a positioning belt. When the correct number of slices are on this belt, it advances and sends its stack of slices to a checkweigher. While this is happening, the slicer continues to cycle but the product feed belt does not advance the cheese block into the blade until the positioning belt is still.

Data exchange

Data from the checkweigher is constantly sent back to the slicer so that it knows how many grams of cheese it is putting in each stack. If a stack is outside of predetermined parameters, the slicer automatically adjusts slice thickness accordingly. The number of slices in a stack won’t change, but slice thickness may go from 1.60 to 1.62 mm, for example. Without a servo-based controls architecture, such on-the-fly adjustments would not be possible, says Weber’s Carsten Reisz.

“Servo-based technology gives the machine maximum control over slicing precision and belt movement,” says Reisz. The smooth acceleration and deceleration of belt speed is crucial, he adds, because at these speeds—up to 130 packages/min—any hasty or jerky movements would cause the stacks of cheese to shift their position on the conveyor belts and cause handling difficulties.

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