07 Machine Setup
07.1 Overview
Before the machine can begin production, it must be configured for the tray format being packed.
Machine setup typically involves:
Installing the correct tooling
Loading the correct recipe
Loading and threading film
Adjusting tray guides
Allowing the sealing tool to reach temperature
Performing the first production run
Each tray format requires a specific tooling set and recipe configuration.
The following sections describe the recommended setup procedure.
07.2 Machine start-up procedure
Before starting the machine, ensure:
The machine has been installed and commissioned correctly.
The operator has read and understood all safety information.
No tools or foreign objects are inside the machine.
All guards are closed.
The machine can then be started as follows.
Step 1 — Check the Machine
Ensure:
The machine interior is clear of objects
All guards are closed
The emergency stop button is reset
Step 2 — Apply Electrical Power
Turn the main electrical isolator located on the electrical cabinet.
This energises the machine control system.
Step 3 — Allow the HMI to Boot
After power is applied:
The HMI will boot
The control system will initialise
The home screen will appear once startup is complete.
Step 4 — Acknowledge the Start Message
The HMI may display a startup notification.
Read and acknowledge the message to continue.
Step 5 — Perform a Safety Reset
Press the blue system reset button located beside the HMI.
The control system will then:
Clear safety alarms
Home all servo axes
Machine motion may occur during this process.
Once homing is complete the machine is ready for setup.
07.3 Load the required recipe
Recipes store the machine parameters for a specific tray format.
To load a recipe:
Open the Operator Menu on the HMI.
Press Load Recipe.
Select the required recipe from the list.
Press Load.
The machine will now configure itself using the parameters stored in the recipe.
These parameters may include:
Tray spacing
Film feed length
Seal temperature
Seal dwell time
Registered film settings
Recipes allow rapid format changes between products.
07.4 Install tooling
Each tray format requires a dedicated tooling set.
The tooling system normally consists of:
Base tool
Top tool
Transfer arms
Some tooling assemblies may be heavy and require two people to install.
Tool Installation Procedure
Press the Change Tool in the operator menu.
The top tool will lower to the tool change position.
Open the machine guards.
Install the base tool onto the base tool pressure plate.
Ensure the arrow on the tool points in the direction of tray travel.
Install the top tool, ensuring alignment with heater connections.
Install the transfer arms.
Secure all hand fasteners.
Close all guards.
Press System Reset.
Press Change Tool again to load the tool into its operating position.
07.5 Load and thread film
Film must be correctly installed before sealing can begin.
Film Loading Procedure
Place the film roll onto the film holder shaft.
Ensure the film is centred on the machine.
Thread the film along the film path shown on the machine.
Keep the film flat and free from creases.
Push the rewind shaft plunger and wrap excess film around the rewind shaft.
Ensure the film nip roller is locked down.
Close the guards.
Press System Reset.
Use Manual Film Feed on the HMI to feed the film through the machine.
Film tension can be adjusted from the HMI home screen.
07.6 Adjust tray guides
Tray guides must be adjusted to match the tray width.
Adjustment Procedure
Place a tray between the tray guides.
Turn the tray guide adjustment wheel.
Adjust until the tray fits snugly without resistance.
Correct adjustment ensures:
Smooth tray feeding
Accurate tray positioning
Reliable sealing operation.
07.7 Warm the sealing tool
Before production begins, the sealing tool must reach its operating temperature.
Wait until the HMI indicates the heater temperature has reached the recipe setpoint.
Typical initial settings when commissioning tooling may be:
These values may vary depending on the tray and film material.
07.8 First production run
Once setup is complete, the machine can begin operation.
Start Production
Press the Start button.
Place trays onto the infeed conveyor.
The machine will then:
Space trays
Transfer trays into the seal station
Seal the trays
Cut the film
Discharge the finished packs onto the outfeed conveyor
The process repeats continuously during production.
07.9 Stopping the machine
To stop the machine:
Press the Stop button.
The machine will complete the current cycle and stop safely.
For emergency stops, press the Emergency Stop button.
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