In the workshop of a snack processing factory in Qujing, Yunnan, bags of walnut kernels wrapped in plateau sunshine are being packaged at a speed of 120 bags per minute. This set of intelligent snack packaging machine solutions tailored by ply-pack is pushing the production model of traditional food companies to a new height of digitalization.
Snacks such as nuts and candied fruits often cause problems such as jamming and leakage in traditional packaging machines due to irregular particle shapes and large fluctuations in moisture content. A company once lost 2.3 tons of raw materials per month due to the high breakage rate of macadamia nuts. After in-depth research, the ply-pack technical team innovatively launched modular packaging equipment, which decouples and reconstructs the three major systems of feeding, weighing, and bag making:
· The flexible vibration plate can automatically adjust the amplitude frequency according to the shape of the material, so that the directional accuracy of cashews and almonds can still be maintained at more than 98% when mixed packaging
· The dynamic weighing compensation module corrects the drop in real time through air pressure sensing, stabilizing the error of the 250g specification within ±1.5g
· The intelligent heat sealing system has a built-in humidity compensation algorithm, which can also ensure the sealing strength of 8N/15mm during the rainy season
In the workshop of a customer in Qujing, the AI visual inspection system is scanning the finished packaged products at a speed of 0.02 seconds/frame. Unlike traditional photoelectric sensors, this system can identify 12 types of defects at the same time:
. Sealing wrinkles are treated by deep learning to establish a library of 128 abnormal models
. Printing misalignment uses sub-pixel edge detection technology with an accuracy of 0.05mm
. When nitrogen is insufficient, the gas pressure sensor links the PLC to automatically shut down
"The most surprising thing is the learning ability of the equipment," said the workshop director, pointing to the self-optimization curve on the control screen, "When processing the newly launched sugar-coated chestnuts, the system independently iterated 7 versions of parameter solutions in just 3 hours."
In response to the trend of small batches and multiple categories in the snack industry, ply-pack launched a flexible production system:
· When changing production, you only need to replace the quick-release components in the mold library, and the production line reconstruction can be completed in 30 minutes
· The recipe management system supports 200 sets of parameter presets, and automatically calls the corresponding process package when switching products
· Equipment OEE (overall efficiency) Increased to 87%, 32 percentage points higher than traditional models
Application data of Qujing customers show:
·The frequency of manual intervention has been reduced from 15 times per hour to 2 times
·The daily production capacity has exceeded 28 tons, an increase of 140% compared with before the transformation
·The packaging qualification rate has remained stable at more than 99.6%
As consumers' requirements for freshness increase, ply-pack is testing the "intelligent fresh-keeping packaging system":
·The built-in gas replacement device can complete the nitrogen filling/deoxygenation switching within 0.8 seconds
·The QR code traceability module records 57 key data from raw materials to finished products
·Humidity-regulating film material extends the shelf life by 40% while reducing the amount of preservatives
"This is not a simple equipment upgrade," said the company's production director, stroking the temperature-controlled conveyor belt, "but through the intelligent snack packaging machine, the entire quality control system has been reconstructed, so that plateau agricultural specialties can truly have the confidence to enter the high-end market."
