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Trayfecta S series Tray and Carton Formers
The new Trayfecta S series tray and carton forming machine uses advanced servomotor drive control for all critical machine motions, allowing the unit to operate at approximately 10% - 15% higher throughput speeds and with greater efficiencies than mechanical-drive systems.
The Trayfecta S series machines also incorporate enhanced ergonomic features, such as a lower carton blank magazine for safer, easier material replenishment.
The new system is available in single and multi-head configurations, continuing the Delkor tradition of safe, reliable and profitable performance.
Advanced servomotor devices control three axes of motion during normal machine operations – carton blank picking, carton transfer, and forming head motions. Servo drives enable each activity to occur at an optimal rate, thereby increasing the overall operating speed of the system.
Highlights
- Ability to form a broad range of tray and carton styles on one machine:
- Lock Style
- Adhesive Style
- Fold-over (Foot-lock)Style
- Setup Box Replacement (SBR) Trays
- Up to four forming heads for high volume production needs
- Spring-load devices on forming heads minimize the risk of material jams
- Pneumatic ejection cylinders
- Tool-less product changeover in 15-20 minutes or less
- Flexible closure options: hot-melt adhesive and mechanical locking tab
- Rockwell Automation control circuitry with self-diagnostics
- Easy-to-access panel with pneumatic controls all in one place
- Color touchscreen HMI control panel with English/Spanish prompts
- Menu driven selection of preset operating speeds and glue dispensing patterns
- Welded ¼-inch cold-rolled steel tubular frame
- Available in stainless steel or powder coated carbon steel construction
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Servo Drive System |
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Carton Blank Pick The vacuum cups on a pick-arm assembly select a carton blank from one of several magazine lanes feeding the machine. |
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Shuttle The pick arm places the blank onto guide rails from which a lugged servo belt moves it forward into position between the forming head and the forming cavity. |
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Adhesive Application For adhesive style cartons, hot-melt adhesive is applied to carton flaps during the controlled shuttle transfer. |
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Forming Head Once a blank is in position, a forming head drives the carton blank downward, through the forming cavity, to create a formed carton. |
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Spring Loaded Cavity Forming activity occurs in a unique spring-loaded forming cavity that prevents product jamming and the costly downtime that can occur. |
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Carton Eject The newly formed carton automatically releases from the bottom of the forming cavity, and drops onto a discharge conveyor. |
- Available Configurations
- 900 Series (Available with 1 forming head)
- 1200 Series (Available with 1, 2, or 3 forming heads)
- 1500 Series (Available with 1, 2, 3, or 4 forming heads)
- Speed Capability (Application Dependent)
- 900 series up to 80 cartons per minute
- 1200 series up to 210 cartons per minute
- 1500 series up to 240 cartons per minute
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Construction
- Available in stainless steel or powder coated carbon steel construction
- Standard fully welded tubular steel frame
- Heavy duty precision servo drives for high speed reliability
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Machine Capacity
- 900 series blanksizesup to 24" W x 30" L
- 1200 series blank sizes up to 36" W x 30" L
- 1500 series blank sizes up to 48" W by 30" L
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Machine Size
- 900 series = 129" length x 60" width
- 1200 series = 129" length x 72" width
- 1500 series = 129" length x 84" width
- Standard discharge height = 36" elevation (carton size dependent)
- Software
- Production monitoring & reporting through HMI touch screen
- Form on-demand photo eye
- 3-color machine status light tower
- Discharge verification sensor
- Magazine level sensor with operator alert
- Adhesive level sensor with operator alert
- English/Spanish HMI language available
- Safety
- Guardmaster category III guard door interlocks & safety monitor relay
- Lock-out tag-out ready air and electrical disconnect
- Air supply shut-off valve with dump
- Two emergency stop buttons
- Ergonomics
- Low level blank magazine
- Ergonomic guard doors with gas shock assist
- Light-weight forming tooling
- Auto retract magazine pressure plate for easy loading
- Swivel-mounted HMI for easy viewing
- Utility Requirements
- 35 amp disconnect @ 480V 60hz 3-Phase (240V/575V Optional)
- 5 CFM @ 80 PSI Air consumption (Maximum)
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Shipping Weight
- 2500 pounds
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Forming Capabilities
- Pneumatic ejection cylinder
- Adhesive style trays or cartons
- Lock style trays or cartons
- Fold-Over (Foot-Lock) style trays or cartons
- SBR (Setup box replacement) trays
- Changeover
- 5-15 minute changeover (Varies with number of heads)
- Tool less quick change parts
- Labels and scales on all adjustment points
- Step-by-step changeover documentation in manual
- Controls & Electronics
- Allen Bradley Compact Logix PLC
- Allen Bradley Panelview 700 “Plus” color touch screen HMI
- Allen Bradley Ultra 3000 servo drives
- Available ethernet connectivity
- 20% minimum spare I/O for easy integration
- Adhesive System
- Nordson ProBlue 10 adhesive melter
- H201/202T zero cavity air-open / air-close application heads or EM-901/902 electronic application heads available
- Wash down heads and hoses available for demanding environments
The Trayfecta formers are well suited to a wide variety of trays, cartons, and cases with either glue-style, lock-style, or fold-over (foot-lock) style construction. This flexibility, combined with the ability to handle paperboard and/or corrugate materials with ease illustrates the ingenuity put into every Delkor Systems machine.
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