Case Packers

Case / Tray Packers

BluePrint Automation

Robotic Series' Robotic Top Loader

Designed to offer you the most flexibility and versatility

What does it do? Our robotic top loaders allow you to place a variety of packaged products directly into cases, trays, crates, and other types of secondary containers.

How does it work? Product is collated into a group using one of our custom collation methods. The product is then picked by a specially designed end-effector. The fully servo-driven robot ensures smooth placement into the secondary container.

What can I pack? Bags, pouches, flow-wraps, thermo-formed containers, as well as a variety of rigid containers such as cartons, cups, bottles, etc.

How productive is it? The top loader can pack up to 300 products per minute when using our Smart-Trak™ collation and up to 300 bags per minute when using our Smart-Bin™ collation. Even higher speeds can be reached with rigid containers. Our latest project involved speeds at 900 cups per minute!

How is the changeover? End-effectors can be changed out within 30 seconds using a simple clamping mechanism. Most settings can be created from the operator panel and saved as unique product codes. The robotic motion is also easily changed and saved as unique product codes.

Why should I buy your robot? Modular means adaptable: A BluePrint robot gives you a modular platform that can be easily adapted to large changes in package and container styles. We recently converted a robot to go from stand-up pouches to thermoform cups.

Fast and reliable: The robot design allows both servo motors (X & Z axis) to be stationary resulting in less moving weight. This means higher speed and less maintenance.

Robotic Series' Swing Machine

The world's most flexible case packing solution for flexible packages.

What does it do? Our Swing Machine has the ability to pack bags and cartons in stand-up and lay-down configurations on the same machine! Only packing your product vertically? Check out our new vertical packer; with its smaller footprint and patented collation method, this system offers total product control!

How does it work?

Lay-down configuration (applies to standard swing machine only): Product is collated into a group using one of our custom collation methods. The product is then picked by a specially designed end-effector. The fully servo-driven robot ensures smooth placement into the secondary container.

Stand-up configuration: Begins with collation and the picking of the product just as the lay-down configuration. Instead of loading directly into the secondary container, the product is placed flat into an intermediary cassette. Cases are tipped towards the cassette and the entire stack is side-loaded into the secondary container.

What can I pack? Ideal for bags, pouches, cartons, etc. A number of our customers currently use the swing machine to pack both bags and cartons on one machine! The new vertical packer is ideal for packing fragile products such as bags of chips and other snacks.

How productive is it? The top loader can pack up to 300 bags per minute when using our Smart-Trak™ collation and up to 400 bags per minute when using our Smart-Bin™ collation system. Even higher speeds can be reached with rigid containers.

Why should I buy your robot? The Swing Machine gives you the ultimate flexibility, in a market place where the customer is constantly demanding different packages and display containers.

Robotic Series' Robotic Vertical Packer

A case packing system, with small footpring and patented high speed collation method for vertical case packing of chips and other snacks!

What does it do? The Robotic Vertical Packer, with its smaller footpring and patented high speed collation method, is a case packing system for vertical case packing of flexible bags.

How does it work? Product is collated into a group using our patented, positive Smart-Trak system. The product is then picked by one of our specially designed end-effectors. The fully servo-driven robot ensures smooth placement of the product into an intermediary cassette. Cases are tipped towards the cassette and the entire stack is side-loaded into the secondary container for a vertical (stand up) presentation. The Robotic Vertical Packer is available with integrated or reusable case erection and closing for new or re-usable cases.

What can I pack? Ideal for packing fragile products such as bags of chips and other snacks.

Why should I buy your Robotic Vertical Packer? Small footprint. Fast: up to 150 bpm!

Robotic Series' Smart Trak™ Collation

The world's most flexible case packing solution for flexible packages.

What does it do? Our smart-trak™ collation system is a vertical race track coupled with quick change over used primarily in our robotic units to index and group individual packages such as bags, pouches, wrapped products, etc. at extremely high speeds. Once a group has been collected it is independently transported to the robotic pick up point. This allows the robot sufficient dwell time (+/- .5 sec.) without having to stop the infeed.

How does it work? Our system, integrated into our robotic top loader or swing machine, uses two groups of holding bins, or pockets, with each group driven by its own servo driven timing belt. We call these groups "shuttle-belts". While one shuttle-belt is indexing to collate your product, the other belt has moved to, and stopped in, the pick-up position. After the product has been picked up, the group moves around the track to continue indexing new packages, while the other group now has moved to the pick-up position.

What can I collate? Bags, pouches, flow-wraps and other semi-rigid or irregular shaped products.

How productive is it? The Smart-Trak™ system can index your product at speeds of up to 300 indexes per minute.

How is the changeover? Each shuttle-belt is simply "clicked out" or "clicked in" to the drive system during a changeover. That's right, a complete changeover (different pitch and/or different number of package per group) can be complete in less than a minute!

Why should I use your collation module in my robot?

Adaptability: No other vertical racetrack on the market can give you both the benefits of the high speed collation, with the ease of a tool-free and under one minute changeover!

Reliability: Extremely simple system, with a minimum of mechanical or pneumatic components, which allows for long term, trouble free operation.

Robotic Series' Smart Bin ™ Collation

High speed accumulating AND collating with Positive Product Placement!

What does it do? Our Smart-Bin™ collation system is used primarily in our robotic units to index and group individual packages such as bags, pouches, wrapped products, etc. at extremely high speeds. A unique combination of high speed accumulating AND collating with positive product placement.

How does it work? Our system, integrated into our robotic top loader or swing machine, allows individual packages like pouches and wrapped products to be received into their own bin for positive containment, placement and transport. Upon receipt of the product into the bin ("on demand system"), the bin is released and individually transported to the collation zone in the pick area of the pick and place robot. As soon as a bin contacts the bin in front of it, it is instantly de-coupled from the main drive, resulting in frictionless, zero back pressure accumulation and pouch collation.

What can I collate? Bags, pouches, flow-wraps and other semi-rigid or irregular shaped products.

How productive is it? The Smart-Bin™ system can index your product at speeds of up to 400 (on demand) indexes per minute.

Why should I use your collation module in my robot? Frictionless and zero back pressure accumulation and collation: With pocketed collation, variables that effect nonpocketed collation systems are eliminated (ie. product build-up, dust and leakers).

Less maintenance: A unique benefit to BluePrint's Smart-Bin system is its extremely simple design, making maintenance virtually a thing of the past.

Very few moving parts.

Robotic Series' End Effectors

Custom Designed for YOU!

Gripper Heads: For products or pack patterns that require picking and packing with a mechanical gripper head, BluePrint Automation can design an end-effector for you.

Vacuum Heads: From the suction cup material selection to the cup spacing, our vacuum end effectors are custom designed for your film, temperature, and other product specific characteristics.

Rotating Heads: For packing patterns that require rotated, or alternating products in the same case, BluePrint Automation offers a high speed, ultra precise, servo rotating end-effector to accomplish the task.

Articulating Heads: For loading patterns that are formed on the end-effector.

MGC Series' Modular Gravity Case Packer

Now even more product control!

What does it do? Our MGC allows you to drop pack a wide variety of bagged products directly into cases, while maintaining phenomenal product control.

How does it work? If necessary, product is first turned using our in-line bag turner. Once product is positioned, it is collated using one of our collation methods. The product is then indexed onto our patented "bomb-door-belts" and released into the secondary container by bomb doors.

What can I pack? Ideal for frozen vegetables, granular products, fresh produce, IQF chicken, as well as a wide variety of other free flowing, heavier products.

How productive is it? The MGC can pack up to 120 bags per minute with our standard collation belt. Higher speeds can be obtained using our High-Speed Shuttle™ collation.

How is the changeover? Changeover is extremely simple, and takes no more than 10 minutes, worst case. All recipe changes can be done through the touch screen MMI, and all mechanical changes are either motorized or have digital readouts for scale. Available with automatic adjustments, with a simple touch of the button all adjustments can be calculated and saved into unique product codes.

Why should I buy your drop packer?

Proven: With over 200 units operating in production environments today, the MGC can stand up to harsh wash down and/or frozen environments.

Accurate and precise: The MGC gives you a more even and nicer looking pack when compared to other drop packers, because of the excellent product control provided by the patented bomb-bay belts.

MGC Series' Rotary Gate Packer

Model RP increases gravity packing speeds tremendously!

What does it do? Our rotary packer allows you to gravity pack a wide variety of packaged products directly into the secondary container, at extremely high speeds.

How does it work? Product enters the RP on a conveyer belt. For slow speeds, and single bag drops, product transfers directly to the rotary gates. For higher speeds, with multiple bags per drop, an indexing gate forms groups of product, which enter the rotary gates as a single group. The gates then rotate at high speed, dropping the row/layer of product directly into the case. If needed, high speed case shifting for multiple row patterns or high case rates, can be provided.

What can I pack? Ideal for bags of fresh or frozen vegetables, IQF chicken and a wide variety of other flexible packaging.

How productive is it? The Rotary Gate Packer can pack at speeds up to 300 bags per minute!

How is the changeover? Extremely simple! All hand wheels have digital readouts to ensure consistency.

Why should I buy your robot?

Simple: The RP has very few mechanical, electrical, or pneumatic components which equals less spare parts to stock and higher productivities.

Small and compact: A floorprint that works with virtually any layout.

VP Series' VHPF

Offers you BOTH HORIZONTAL & VERTICAL packing on the SAME MACHINE!

What does it do? Our VHPF system allows you to pack STAND-UP AND FLAT PACK on the SAME MACHINE with minimal changeover.

How does it work? The new VHPF is based on the existing VP/F machine, a vertical only case packer that quickly became the standard case packer for the potato industry. The proven VP/F has not been changed to create the VHPF; the horizontal pack mode has simply been added onto the vertical packer by adding a flat-pack-cassette. The VHPF still operates the same way in its vertical mode. However, when flat packing, a flat-pack-cassette is simply lowered in front of the loading mandrel. Once in position, a pre-stacked caseload can be gently inserted into its case. Changeover between vertical and horizontal mode takes only 3 minutes. A wide range of vertical and horizontal pack patterns can be realized with the new VHPF. The capacity of the new VHPF is just as amazing as its versatility. Large 6 lb food-service bags can be packed vertically at a production rate of 65 bags per minute. Retail bags can be packed flat at a production rate of 80 bags/min.

What can I pack? Ideal for packing bags of frozen potato products such a retail and service food bags of french fries.

How is the changeover? Changeover can be accomplished in only 3 minutes!

Why should I buy your VHPF? Tightest case cube utilization in industry. Reduced breakage. Easy changeover. Changeover is facilitated by hand wheel adjustments, quick release handles and touch-screen operator interface.

VP Series' VP

Designed to offer you the most flexibility and versatility.

What does it do? Our VP system allows you to pack a large variety of bagged products standing up into cases, trays, crates, and other types of secondary containers.

How does it work? Product is indexed onto out patented bomb-bay belts using rotary gates. Bags are then transferred to an indexing cassette. The product accumulates in the cassette until a full case load has been reached. The empty case is tipped towards the cassette and product is side pushed into the pre-tipped case.

What can I pack? Ideal for bags of snacks such as potato chips and pretzels, as well as other fragile products packed vertically, available with reusable case option.

How productive is it? The VP can pack up to 90 bags per minute. With our high-speed model (VP-HS), speeds of up to 130 bags per minute can be reached.

How is the changeover? The VP can a wide variety of bags and case sizes. Changeover can be accomplished in under ten minutes. For case size changes, a modular cassette assembly is easily removed, and another inserted. Simple and Fast!

Why should I buy your vertical packer?

Great value: The VP combines a small narrow foot print with great functionality for a very reasonable price.

Proven: Over 200 successful installations world-wide handling and vertically packing fragile products.

Flexible: Loads a variety of bags and case sizes.

VP Series' VP/HS

Designed to offer you the most flexibility and higher speeds.

What does it do? Our VP-HS system allows you to side-load a variety of packaged products directly into cases, trays, crates, and other types of secondary containers.

How does it work? Product enters the packer and is transferred 90° by a unique cam profile, servo driven belt system. Bags are collated with adjustable overlap on our "bomb belts" which swing away after a layer is collated. The product accumulates in a holding cassette until a full caseload has been reached. The empty case is tipped towards the cassette and product is side pushed into the pre-tipped case.

What can I pack? Ideal for bags of snacks such as potato chips and pretzels, as well as other fragile products packed vertically, available with re-usable case option.

How productive is it? With our high-speed model, speeds of up to 130 bags per minute can be reached! Unmatched in the industry!

How is the changeover? Changeover can be accomplished in under ten minutes. For case size changes, a modular cassette assembly is easily removed, and another inserted. Simple and fast!

Why should I buy your VP/HS?

Flexible: Large variety of bags and case sizes

Proven: Over 100 successful installations world-wide handling and vertically packing fragile products.

Excellent small bag handling: For products such as one ounce bags of potato chips.

VP Series' VP/F

The ideal frozen potato packer, a vertical case packer for high-speed case packing of flexible bags.

What does it do? Our latest generation VP/F case packing system allows you to load products standing up into cases.

How does it work? Bags are settled with out specially designed square roller. Each bag is then positioned into a side-loading cassette by means of a servo transfer plate (patent pending). The servo plate comes out from under the in-feed conveyor and gently carries the bag forward at a very low speed. Once the bag is on the plate, it retracts at lightening fast speed after which, the bag positions itself in the cassette. A full load is side loaded into a 90° tipped case. With an optional built-in lane dividing unit, it can pack 1 or 2 x X pack pattern.

What can I pack? Ideal for bags of frozen foods such as french fries, tater tots, and other heavier frozen and fragile products.

How productive is it? The VP/F cruises at 60 (5 or 6 lbs.) bags per minute when packing a 1 x 6 pattern. Higher speeds can be achieved on 2 x X patterns.

How is the changeover? Changeover is our new and approved VP/F is tool-free, and extremely simple! For case footprint size changes, the lift plate and pusher plate are snapped out, and a new set snapped in. After a quick product code change on the HMI, YOU ARE READY TO GO! For larger case footprint changes the cassette assembly (2 parts) can be changed out using all click-in attachements. A few adjustments are that is needed. A full change over can be done in under ten minutes.

Why should I buy your VP/F?

Speeds yet unchallenged. Gentle with product. No fast transfers assures product is evenly distributed throughout the bag. Almost all motorized allowing for low maintenance.

VP Series' Row Stacker

Side load stacker is simple and dependable.

What does it do? Our Row Stacker allows you to side-load a variety of packaged products in a single vertical row, directly into cases.

How does it work? Product is pre-staged then transferred into a holding cassette. The product accumulates in the cassette until a full case load has been reached. The empty case is tipped towards the cassette and product is side pushed into the pre-tipped case.

What can I pack? Ideal for pillow bags and gussetted pouches into one row formations, such as 1 x 12, 1 x 6, etc.

How productive is it? This system is proven itself in production, at rates up to 120 BPM.

Why should I buy your vertical packer?

Very simple, few moving parts. Excellent value, coupled with extremely small footprint.

Pack Assist Flexible Bag Collator

Changeover in under a minute!

What does it do? Our pack-assist machine collates your product directly from your bag maker, allowing the operator to place a full row of product in the secondary container at once. It replaces conventional rotary pack-off tables, where product orientation cannot be maintained.

How does it work? Product arrives via a side-adjustable chute on the inclined belt conveyor. Bags are fed into a patented indexing wheel, which positions them vertically, in a single file, on a discharge conveyor for the operator.

What can I pack? Ideal for snack food bags such as potato chips, pretzels, etc.

How productive is it? The Flexible Bag Collator collates up to 140 bags per minute.

How is the changeover? Changeovers involve only the turning of a simple switch, adjusting the indexing wheel speed.

Why should I buy your collator?

Increase production, not labor. In many cases the bag maker output is reduced because of limitations of hand packer(s). With the collator the bag maker speed can be increased without adding labor.

The patented starwheel gives perfect product orientation, even for small on ounce packages. There is no comparison available on the market.

Crate Loader

Loads trays of fresh product into plastic crates

What does it do? The crate loading system is specially designed for loading plastic (washable circulation) crates with trays of fresh products (such as meats, salads, fish, cheese, etc.).

How does it work? This system incorporates a fully automatic crate de-stacking system for the empty crates and a stacking system for the filled crates. It is very flexible and handles a wide range of tray sizes and loads them into plastic crates. The System is controlled via the full colour touch screen of the Industrial PC (IPC).

How is the changeover? Changeover is fully automatic without changing any parts.

Why should I buy your crate loader?

Reliable and maintenance friendly.

Maximum accessibility for easy cleaning.

Easy operation and quick changeover.

Lengthwise and crosswise packing at same layer.

Vision Guided Robotics High Speed Delta Robot

Incredibly fast - incredibly accurate.

What does it do? The high speed, delta style robot is the ideal solution for dynamically (on the fly) moving single products from one place to another, when the infeed cannot be predicted, or is random, at extremely high speeds.

How does it work? The robot is an overhead supported, three or four axis robot, with a large working envelope. Product enters the working envelope after being detected by a highly accurate camera system for orientation. The robot takes the input from the camera, goes directly to the product and re-orientates the product while placing it in the location or container specified, all at speeds exceeding 120 picks per minute!

What can I pack? Random or orientated, wrapped or unwrapped, firm or flexible products up to 1Kg. In weight.

How productive is it? Unsurpassed in built in flexibility, extremely fast cycle times, minimal wear, and superior quality contribute to the highest productivity in the industry.

How is the changeover? For most applications, changeover only involves a quick product change on the MMI, a matter of minutes!

Why should I buy your high speed delta robot?

Extremely high cycle times, coupled with extremely high accuracy. Can be employed in a wide variety of applications, throughout your plant!

Vision Guided Robotics Multi Axis Scara Style Robots

Dynamic casepacking of variety of products.

What does it do? The Scara style robot is a tabletop, four-axis machine that allows for dynamic case packing of a wide variety of products. It can be incorporated with a vision system if necessary for random product feeds.

What can I pack? A large variety of flexible semi-rigid or rigid packages, at various temperatures and characteristics, at payloads up to 5.5 kg.

How productive is it? The robots are extremely fast, with joint (Axis) speeds of 670 degree per second and 43 inches per second down hand stroke speed possible. Depending on range of motion required, and product characteristics, extremely high packaging speeds are attainable.

What is the changeover? Changeover is primarily handled through the H.M.I and software. For some products a quick end effects or may need to be changed.

Why should I buy your multi-axis robot?

Maximum flexibility with minimum development expense. The advanced software takes care of it for you. High small working footprint required takes up less space in your facility.

Douglas Machine Inc.

Douglas Case Packer and Tray Packer solutions are virtually limitless. For nearly four decades, Douglas Machinery has provided dependable solutions for a variety of product types, sizes, and pack patterns.

Servo and/or mechanical drives, patent-pending and traditional metering techniques, and modularity add up to flexible high performance that's simple and reliable. Various product accumulation systems, servo and mechanical lane dividers, product or tray stackers, and staging loaders allow for the widest range of application solutions possible.

Axiom Intermittent Motion Servo Case/Tray packer

Put maximum speed and flexibility to work for you with Axiom™ Intermittent Motion Servo Case Packers and Tray Packers. Servo functions reliably and accurately pack cartons, bottles, cans, jars and flexible packages 50 percent faster than mechanical functions. Innovative technology delivers unprecedented flexibility, easily adapting the Axiom™ to changing market demands.

Standard Features

	Speeds to 45 cases/trays per minute.
	Modularity provides maximum flexibility for evolving and uncertain product life cycles.
	Next generation servo functions for repeatable changeovers and simple fault detection and recovery.
	Forty-five percent fewer parts for less maintenance and reduced sanitation time.
	Products are handled in the most efficient manner with our exclusive Smartrak™ Steady Stream Infeed or industry-proven infeed systems.
	Efficient patented pinless metering and industry proven metering.
	Sanitary stainless steel frame construction for longevity and corrosion resistance.
	Small footprint saves 15 to 30 percent in valuable floor space.

Options

	Velocity™ High Speed Stacker provides continuous product flow at 600 products per minute, 60 percent faster than traditional stacker designs.
	Extended capacity magazines reduce loading frequency.
	Servo or mechanical lane dividers handle virtually any product shape or size.

Mechanical Intermittent Motion Case/Tray Packing

Applications for our mechanical Intermittent Motion Case Packers and Tray Packers are virtually limitless. Our innovative design techniques yield solutions that are less complex, more reliable, and easily accessible. Lower operating and maintenance costs and higher efficiency ratings ensure a faster return on your capital investment.

Standard Features

	Products are handled in the most efficient manner with our exclusive Smartrak™ Steady Stream Infeed or industry-proven infeed systems.
	Efficient product metering and accumulation methods ensure minimal surge pressure, stable product handling, and less product damage.
	A variety of innovative product loading techniques ensure your products are loaded at speeds to 30 cases per minute (application dependent).
	Ideal for a vast range of products such as cans, bottles, cartons, and flexible pouches.
	Flexible changeover techniques range from simple multiple size rotating changeover guides to threaded screws, handwheels and handknobs with position pointers and scales.
	Single and optional double-tier solutions for a variety of product sizes, flap styles, and pack patterns.

Options

	Velocity™ High Speed Stacker provides continuous product flow at 600 products per minute, 60 percent faster than traditional stacker designs.
	Extended capacity magazines reduce loading frequency.
	Stainless steel construction and component specifications for washdown environments.

Intermittent Motion Case/Tray Packing

Put maximum speed and flexibility to work for you with Douglas mechanical Continuous Motion Case Packers and Tray Packers. We are pleased to offer product versatility and innovative infeed and metering systems to fulfill your corrugated packaging needs. Mechanical or servo functions guarantee maximum results for your packaging line.

Standard Features

	Products are handled in the most efficient manner with our exclusive Smartrak™ Steady Stream Infeed or industry-proven infeed systems.
	Efficient product metering and accumulation methods ensure minimal surge pressure, stable product handling, and less product damage.
	Tray or wraparound direct or barrel cam load ensures your products are loaded at speeds to 85 cases per minute or over 100 trays per minute (application dependent).
	Ideal for a vast range of products such as cans, bottles, cartons, and flexible pouches.
	Flexible changeover techniques range from simple multiple size rotating changeover guides to threaded screws, handwheels and handknobs with position pointers and scales.
	Single and optional double-tier solutions for a variety of product sizes, flap styles, and pack patterns.

Options

	Velocity™ High Speed Stacker provides continuous product flow at 600 products per minute, 60 percent faster than traditional stacker designs.
	Extended capacity magazines reduce loading frequency.
	Stainless steel construction and component specifications for washdown environments.

Read more about BluePrint Automation

For more information regarding these equipments, please contact Nicolas Michel, Sales and Service Representant, at 450-922-6622, ext. 170.