First sliced products then whole cuts: a World First for flexible slicing & cutting on a single machine.
Cheese producers are often faced with the challenge of having to produce a wide variety of shapes economically and flexibly while also maximizing output—ideally on a single production line. Which is precisely where Weber comes into its own, as a systems provider with its end-to-end multi-faceted concept. Weber can deliver practical, efficient, and future-proof processing and packaging solutions across the entire process chain. In keeping with the interpack slogan of ‘Expect More – than just packaging’, Weber was able once again to demonstrate clearly that customers are entitled to expect far more than just individual machines or standalone packaging solutions. A great example of just such a solution was the high-performance line for cheese applications exhibited at this trade fair. This line satisfies several current customer and market requirements at one and the same time while also showcasing a number of highlights and world firsts. Cheese producers looking to manufacture both sliced portions and bars flexibly, precisely, and at maximum capacity on a single line will discover that this concept offers a unique solution for the entire process from de-foiling and dividing the cheese blocks to attractive, safe, and sustainable packaging. This end-to-end solution delivers maximum flexibility in day-to-day production while also increasing output, reducing capital expenditure and boosting the return on investment (ROI).
De-foiling and dividing: Automated cheese preparation for maximum efficiency.
More performance, optimum automation and higher availability—processing and packaging cheese has never been more cost-effective. The efficiency and precision of this line-based solution are unsurpassed, at a standard of quality that is second to none. This is made possible by the multitude of ingenious innovations embodied in this line, first and foremost being the new Weber weDEFOIL 5000. The automatic de-foiler is an ideal addition to the Weber portfolio, integrating as it does a further process step into Weber’s range of end-to-end production lines. The weDEFOIL can remove the film from up to six blocks or wheels of cheese per minute. After precise sensor-based measurement, the cheese is seamlessly slit around its perimeter by a robotic system, and the film is then expertly removed by a second robot during the pre-indexing phase. Thanks to an integrated blade-changing station, blades can be changed safely, ergonomically and with minimal use of tools.
The Weber weDIVIDE 7000 cheese block divider is connected directly to the new Weber de-foiler. Regardless of whether the cheese is in euro block or cheese wheel format: The weDIVIDE unit divides the unprocessed cheese into uniform blocks and prepares these for further processing. It does so in a way that achieves the highest possible yield—while minimizing the need for personnel at the same time. Depending on the product, either a wire or a blade can be used for cutting to ensure consistently clean and optimum portion shapes. This comes with a remarkably sophisticated technical feature. To achieve this yield-optimized division of cheese products, the cutting frame is able to move horizontally as well as vertically. The horizontal movement ensures consistent portion sizes and, consequently, a uniform presentation of the portions within the packaging. Vertical adjustment is used in particular to control the weight of the split blocks: If the weight of the cheese blocks is identical across all lanes, empty packaging is avoided in the subsequent process. This saves resources, reduces waste, and increases the efficiency of the entire line. Depending on requirements, the Weber cheese block divider provides various functionalities and options: from integrated manual loading to sorting, buffering and trimming on the sides. Manual loading is possible as standard without the need for an additional module—this reduces the length of the line and lowers the cost of investment. The weDIVIDE system also delivers impressive levels of operational safety: Automatic alignment of the cutting frame and dies prevents operating errors, supported by reliable detection and reporting of broken cutting wires.
Optimum preparation for the best slicing results
Precise scanning is critical for optimum and high-performance processing of raw material in order to achieve maximum yield. The Weber weSCAN 5500 scanner, which is integrated into the slicer, is therefore part of this production line concept. The weSCAN 5500 uses laser scanning technology that permits absolute scanning precision at a maximum scanning speed. Higher yields and perfect slices are the result of this technical masterpiece. Thanks to the integration of scanner and slicer, food processing companies benefit from savings in line length and less effort for cleaning and maintenance. The scanner’s open design also ensures excellent accessibility and allows for quick, efficient cleaning. The weSCAN 5500 is operated via the operating terminal of the slicer, which improves user friendliness and ensures optimum accessibility of the scanner. Clear 3D visualization of the scanned product also makes it much easier to use.
A World First combines cutting & slicing on a single machine.
With its Weber weSLICE 9500 slicer and its new Weber PowerCut system, Weber is defining new standards in cheese processing, combining maximum flexibility with top performance. The Weber weSLICE 9500—the flagship model when it comes to precisely slicing demanding products in the highest quality and with the highest performance—features DirectDrive technology, which ensures precise product feeding, uncompromising slicing quality, exact portion weights, and maximum product integrity. Over and above that, the Vario technology of the weSLICE 9500, which enables track-independent carriage, contributes to this unique level of performance while ensuring the highest possible portioning accuracy at the same time.
Maximum flexibility in day-to-day production and improved cost-effectiveness: These are just two of the many benefits that this high-performance production line concept can provide to cheese producers. All of this is made possible by the Weber PowerCut System, which was unveiled at interpack as a world first. If production calls for cheese bars instead of sliced portions, it is a simple operation to combine PowerCut cutting technology with the slicer on the line. Changing over from the Performance Slicing System to the hygienic PowerCut System—also made entirely of stainless steel—is a quick and safe operation. The transport and storage trolley simply docks precisely onto the slicer. The cutting unit can then simply be pushed, sliding it into the slicer’s slicing throat. Even at the highest performance levels and across up to four tracks, the PowerCut system delivers perfectly cut, uniform cheese bars. Provided the characteristics of the raw product permit this, the entire cheese block can be cut into pieces of the correct weight through the smart interconnection of the line modules, ensuring that the raw product is fully utilized. Thanks to the unique flexibility of this 2-in-1 line and the maximum product yield, cheese producers benefit from an unrivaled return on investment. Of course, the weSLICE 9500 is also available with just the PowerCut system or just the Performance Slicing system.
Maximum automation for maximum efficiency
Once the product has been cut and portioned to precise weights, portions are transferred to the Weber weWEIGH 5000 scale, which weighs them individually and with high precision. As is typical of Weber, this scale also stands out thanks to its fully open design, which offers optimal conditions in terms of hygiene and user-friendliness.
After the cheese bars or sliced portions have been gently conveyed further by the Weber CompactBuffer thanks to the intelligently controlled acceleration and deceleration, they are placed securely and with pinpoint accuracy into sustainable flexible film packaging using a wePICK pick robot—the fastest delta robot in its market segment. No other picker is more powerful and yet precise and reliable. To increase production capacity, a double vacuum pick-and-place gripper was also incorporated into this production line design. Furthermore, the new, camera-controlled adjustment of the mounted gripper matching the selected line program contributes to operational safety and protects the technology against faults due to incorrect operation—an extra plus in safety. Weber’s commitment to perfect mechanical and software integration is particularly evident with this automatic Weber loading solution: The double picker can be integrated into the Weber wePACK 7000 packaging machine in a unique way. Minimal space requirements, more efficient motion sequences of the robot for faster process times and higher performance, easier and faster cleaning of the floor in the production hall and best accessibility are just a few of the many advantages of this integration.
Safe, sustainable and high-performance packaging.
The Weber wePACK 7000 takes care of the safe and sustainable packaging of the cheese portions. This thermoforming packaging machine sets new standards for output as well as quality, and—through the use of modern servo technology—it is also extremely energy efficient. As part of this line, Weber presented a sustainable flexible film packaging solution—a type of packaging that is widely used in the market for cheese bars, whether vacuum-packed or as modified atmosphere packaging (MAP). Of course, the wePACK 7000 can be adapted rapidly to suit different pack sizes and film types. This is of great benefit, especially on highly flexible lines like this one because it makes it quick and easy to switch between rigid and flexible film—depending on whether the line is producing cheese bars or sliced cheese. The new movable cross-cutters also contribute to this unique flexibility. Thanks to their ability to move dynamically, it is now possible to separate the same number of packs using only half the number of punch actions. For food producers, this halves the investment costs for the cross-cutting of packaging lines. In addition, programmable stop positions ensure process reliability. With the appropriate cutting set, these movable cross-cutters can process rigid as well as flexible films. The various cutting sets can be adapted quickly and easily to suit the type of film being used.
For printing the top film, the Weber weMARK has been integrated in this line concept – the fastest transfer unit for thermal ink jet print heads on the market. The integrated x/y traversing unit can also be used with all conventional ink jet printers. The display of the printer control panel can be mirrored conveniently onto the Weber HMI, which facilitates ergonomic operation without long walking distances as well as complete operation and print management from a single display. Naturally the new Weber x/y transfer unit comes with a standardized "no product, no print" function to reduce running costs. If the print head supports it, weMARK also permits bi-directional printing. In practice, food processing companies benefit from a reduction of process-related waiting times and maximized output.
To maximize the quota of ok packages, Weber has developed the new Portion Positioning Control (PPC). This camera-based system checks the portion positions in the loading area. If portions are in an incorrect position, for example near the sealing seams, and need to be repositioned, PPC transmits this information via multi-directional communication to other line components such as the slicer, pick robot or infeeder. This allows them to respond to the information and misalignment by adjusting the placement parameters for the rest of the production process accordingly, which optimizes the positioning of the portion within the packaging. In addition, PPC can be used to address one aspect of package quality control, as it can detect loose product pieces located in the sealing area of the package once they reach a certain minimum size.
Uncompromising integration and networking.
In addition to innovative and powerful technology, the possibilities of integration and networking result in versatile advantages and added value for food processing companies. These range from an increase in quality and efficiency, to an increase in transparency and process reliability, to the reduction of operator requirements on the line. The unobstructed flow of data enables, for example, targeted portion tracking with automatic corrections to increase efficiency. The line operators can see where each portion is and what condition it’s in at all times. Furthermore, operators can decide how to deal with portions that have incorrect weight. All information, programs and settings can be accessed at one of the control panels at any time and from anywhere. With the help of Weber OneControl technology, it is possible to control the entire line from any operating terminal. This unique software integration even includes third party components. This means that a recipe request always applies to the entire line and the overarching line control via Weber OneControl makes the entire process simpler, faster, and safer. This intelligent multi-directional communication ensures comprehensive future reliability of the line. The intuitive HMI also ensures easy operation.
But that's not all: in combination with the Weber Digital Factory Solutions, the effectiveness of production can be significantly increased even more and comprehensive transparency of the production process can be ensured. That is true integration, which is truly holistic.
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