The Marchesini MCP840 is an automatic monoblock machine, suitable to receive cartons from an infeed motorized conveyor belt, collate and introduce them into case, seal it with self-adhesive not overlapping tape and make the cases palletisation.

Casepacker Section

• The casepacker section is made of a solid supporting frame where all Casepacker and Palletizer mechanical mechanisms and motors are contained. The machine has been designed and manufactured following the balcony type construction to reduce mechanical maintenance and lubrication. Mechanical parts are protected against dirt and dust because they are isolated from the working area and the case transport unit.
• The electric panel of the monoblock is included inside a cabinet placed on the Casepacker rear side and makes possible accessibility to all mechanisms.
• All the Casepacker-Palletizer motions are driven by servo motors which are controlled by the PC.
• Adjustments for case size change over under ‘B’ Width and ‘H’ Height quotes are made through servo motors with command directly from the operator panel. “A” Length is automatically adjusted by selecting the format from the PC. The hopper, the Pick & Place suction plate and the pusher have to be replaced when changeover is made.
• Quick lock size parts with reduced use of tools.
• Designed and manufactured in accordance with GMP norms, the machine is delivered with the CE certification.

Collation

Cartons, coming from the upstream machine, are horizontally collated on a conveyor belt placed at 870 +/-50mm (34.25” +/-1,96”) of height where they are transferred directly into the hopper by a Pick & Place which makes cartons stacking from bottom to top (this operation permits to obtain high stability of the carton’s layers). Carton pickup is detected at each collating cycle in order to assure the final cartons configuration. Machine stop in case of wrong cartons quantity during pickup. 

Once collation is completed, the pusher and the hopper, mechanically driven, move towards the open case to achieve cartons transfer. 

Case Feeding System

The case magazine is a 1750 mm (68,89”) long conveyor belt placed at 450 mm (17.71”) from the floor level, really easy to load. The belt allows to place more stacks of flat cases over all its length and one stack in the pick-up area. The magazine is motorized with automatic transport of the stacks of cases to the pick-up area.

Cases are picked up from the top of the stack by a picking arm which automatically adjusts its position up to pick up the last flat case. Afterwards, the case is transferred to the forming and loading station by a vacuum system. Case forming is made in the loading area by the combined movement of the picking arm.

The case is squared up by two sets of vacuum suction cups located on the opposite sides of the case itself (upper and lower sides). This allows to handle a wide range of cardboard boxes sizes, without the use of change parts. After the case has been opened, it is kept in position by the suction cups of the opening system, until the product introduction. Based on the selected size, the strokes of the picking arm and case transport chains are automatically adjusted without neither size parts nor manual settings.

Case Closing  

After the carton’s introduction inside the case, the latter is transferred to the flap folding and tape closing stations by means of transport chains (Hot melt version is available as option).

Case closing does not require, when changeover is made, neither adjustments nor replacements of parts. The setting up of the carton H quote, made from the operator panel, acts simultaneously on the distance (automatically adjusted) between the taping units.

No cases remain within the transport area with the exception of the one waiting to be filled.

Case Transfer

The closed shipper is discharged on the motorized roller conveyor for its transfer to the Palletizer picking station. On demand, several optional devices can be installed on the conveyor: case turning device, checkweigher, printers, barcode readers and labellers.

Palletizing Section

• The Palletizer is capable of loading, on standard pallets, the cases coming from the casepacker section of the monoblock machine.
• The use of the anthropomorphic “Robotic Arm” at 4 free side movements, improves machine performances and flexibility of application.
• The arm, made of anodized aluminium plates, offers sturdiness and rigidity to the machine construction during the cartons picking & place movements.
• The Pickup head works with vacuum and free rotation over 360 degrees.
• Manual empty pallet loading and manual full pallet discharge within dedicated guides.
• The machine is prearranged for the installation of automatic pallet loading and discharge functions.

Installed Safeties

• Emergency circuits and protections with safety level “PLd Cat.3”.
• Safety guards in methacrylate, integrated in the machine frame with safety interlocks on all opening positions, with machine stop in emergency mode and release of compressed air.
• Overload torque control on all motors.
• Casepacker infeed: minimum load control, the machine remains idle if product is missing and starts automatically if product flow is restored; maximum load control on the infeed conveyor with stop of the upstream machine upon receipt of a signal detecting maximum load of product.
• Minimum load control of the cases inside the magazine with acoustic pre-warning signal and machine stop.
• Control for the unsuccessful case opening with machine stop.
• Control for the adhesive tape breaking with machine stop and acoustic signal in case of tape reel end.
• Overload control for full case discharge with machine stop and automatic start after free discharge has been restored.
• Visual and acoustic signal of empty pallet ready to start loading.
• Optical barrier safety at pallet discharge.