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Repak RE20 - User Manual

Repak RE20
144 pages
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Repak
Phileas Foggstraat 18, 7821 AK EMMEN, The Netherlands.
Phone +31 (0)591 668010, Fax +31 (0)591 676076, www.repak.nl
User Manual
for the start-up and operation of the
Thermoforming Packaging Machine
part 1: operator

Table of Contents

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Summary

Introduction

Machine Functionality

Explains the primary purpose and operation of the Repak RE20 packaging machine.

Technical Specifications

Machine Performance Standards

Details the operational capabilities and conditions for the machine.

Included Items in Order

Lists the components and items included with the machine when delivered.

Machine Disposal Procedures

Preventive Measures and Safety Instructions

General Safety Guidelines

Provides essential safety instructions for operating the machine and working with it.

Intended Use and Prohibited Operations

Defines the allowed applications and restrictions for machine usage.

Explanation of Danger Symbols

Explains the meaning of various danger symbols found on the machine.

Machine Safety Systems

Details removable and fixed safety covers that protect machine components and users.

Emergency Switch Operation

Details the function and activation of the emergency stop button for immediate machine halt.

Machine Description and Components

Packaging Process Overview

Details the step-by-step process of packaging using the machine's film and stations.

Machine Frame Construction

Explains the modular construction and materials used for the machine frame.

Bottom Film Unwind Unit

Describes the unit for unwinding the bottom film roll and feeding it to the machine.

Forming Station Description

Details the forming station where film is shaped into package cavities.

Loading Area Description

Describes the area between forming and sealing stations where products are loaded.

Top Film Feed and Control

Explains the top film unwinding unit and the photocell/film brake system.

Sealing Station Description

Details the sealing station where packages are sealed with top film.

Cross Cutting Systems

Describes the systems used for separating sealed packages crosswise.

Longitudinal Cutter Systems

Details systems for separating packages lengthwise, including rotary and squeezing knives.

Discharge Conveyor Belt

Explains the function of the conveyor belt that removes cut packages.

Control Cabinet Details

Describes the control cabinet containing the machine's electronic and pneumatic systems.

Film Edge Trim Removal

Details systems for removing film trims from the packaging process.

Control Panel and Operation

Control Panel Interface

Explains how to use the touch screen interface for machine operation.

Machine Operating Menus

Describes the four main groups of functions within the machine's menus.

Switching Functions

Lists and describes the functions of various control buttons for machine operations.

Operator Menu Navigation

Lists the submenus and functions accessible from the operator menu.

Program Selection Menu

Allows selection of different pre-configured programs for packaging specific products.

Machine Settings Adjustment

Allows adjustment of machine parameters like pause times and switch points.

Operation Sequence Setup

Details the available settings for the forming and sealing station's operation sequences.

Temperature Setting Adjustment

Sets temperature limits and defines actions for 'temperature too high' conditions.

Vacuum Settings for Sealing

Configures vacuum and gas pressures, timings, and control parameters for sealing.

Alarm History Log

Provides access to a log of the last 1000 alarms for troubleshooting.

Operating the Machine

Machine Start-up Procedures

Details the staged plans for turning the machine on and its two operational modes.

Fitting Film Rolls onto the Machine

Step-by-step guide for loading both bottom and top film rolls onto the machine.

Photocell Setting for Print Alignment

Instructions for setting the photocell to detect marks on printed top film.

Machine Shutdown Procedures

Describes various procedures for turning the machine off for brief or long periods.

Monitoring Machine Operation While Running

Details operator tasks and points to monitor while the machine is running.

Energy Saving Operation Strategies

Provides tips for reducing energy consumption by shutting down the machine when idle.

Emergency Switch Operation Details

Provides more detailed information on the function and location of the emergency switch.

Machine Operational Modes

Explains the two operational modes: automatic operation and manual film infeed.

Pre-Start Checks

Lists essential checks to perform before turning the machine on to prevent issues.

Automatic Operation Startup

Details the step-by-step process for starting the machine in automatic operation mode.

Film Infeed Mode Startup

Describes the startup procedure for the manual film infeed operational mode.

Single Stroke Mode Startup

Outlines the startup procedure for the single stroke operational mode.

Restart Procedures for Different Stops

Covers restarting after machine stop, safety circuit failure, or emergency stop.

Cleaning and Maintenance

Cleaning Guidelines and Methods

Provides essential guidelines for safe and responsible machine cleaning.

Suitable Cleansers and Disinfectants

Lists recommended cleansers, pH values, and prohibited substances like chlorine.

Machine Washing Setting

Details the special machine setting optimized for cleaning operations.

Disinfection and Calcium Deposit Removal

Provides methods for disinfecting and removing calcium deposits, including rust removal.

Overview of Maintenance Procedures

Outlines the two parts of the maintenance system: procedures and logbook.

Procedure 1: Preparations for Cleaning

Details the preparatory steps required before cleaning the machine.

Procedure 1: Water Protection Steps

Instructions for protecting water-sensitive parts during cleaning operations.

Procedure 2: Cleaning and Maintenance Steps

Outlines the general steps for daily cleaning and maintenance.

General Maintenance Instructions

Provides overall guidance and precautions for performing maintenance tasks.

Conveyor Chain Maintenance

Details maintenance for the conveyor chain, including tension and lubrication.

Lifting Station Maintenance

Details lubrication checks and procedures for lifting stations, including central systems.

Hard Foil Stamp Maintenance

Outlines maintenance procedures for the hard foil stamp, including lubrication.

Procedure 2: Daily Cleaning and Maintenance

Details specific daily tasks for cleaning and maintaining the machine.

Procedure 3: Preparing Machine for Operation

Steps to prepare the machine for operation after cleaning.

Maintenance and Cleaning Logbook Recording

Instructions for recording all maintenance and cleaning activities performed.

Troubleshooting and Status Lines

Overview of Status Lines and Failures

Details how environmental conditions can cause machine problems and their solutions.

Status Line Error Message Overview

Lists possible error messages, their causes, and suggested solutions.

More Status Line Error Messages

Continues the list of error messages and their troubleshooting steps.

Addressing Film Defects and Breakages

Provides actions to take when film breaks or slips, including stopping the machine.

Explanatory Glossary of Terms

Glossary Terms A-F

Defines terms related to chains, air, controls, conveyors, cutting, danger zones, drives, and fillers.

Glossary Terms F-S

Defines terms related to forming, frames, gas, guillotines, infeed, lifting systems, and modules.

Glossary Terms O-S

Defines terms related to operation, operators, photocells, PLCs, products, safety, sealing, and status.

Glossary Terms S-W

Defines terms related to support, systems, touch screens, transport, vacuum, and washing.

Appendix: Technical Information Documents

Appendix Document References

References technical information documents for vacuum pump operation and food contact compliance.

Repak RE20 Specifications

General IconGeneral
BrandRepak
ModelRE20
CategoryPackaging equipment
LanguageEnglish