Product innovation: Deep-drawing packaging machine R 900

With the R 900, Multivac introduces a new model of its thermoforming packaging machines, which is particularly suitable for large products that require a very high packaging cavity. The R 900 was developed as part of a customer project with a medical device manufacturer who packages multi-component systems for the operating room.

The OP sets packaged on the new R 900 by Multivac consist of ready-to-use components such as syringes, scalpels, clamps, suture material, etc., assembled according to indications. These multi-component systems are initially packaged in a plastic box or a flexible pack and then wrapped in sterile operating room sheets.

“To enable the complete set, which can be up to 15 centimeters high and often consists of 2 or 3 layers, to be automatedly packed on a high-performance thermoforming machine, we developed a new machine concept that allows a deep draw of 450 mm. The machine frame height is therefore 1300 millimeters. On the first customer machine, this enabled the forming and sealing of large package formats ranging from 200 to 600 millimeters in width, 430 millimeters in length, and up to 450 millimeters in height,” explains Natalie Schmid, Product Manager at Multivac.

The use of the new thermoforming machine, which was developed in close collaboration with the user, offers significant advantages to the medical technology provider. Previously, the products were packaged in special pouches, which often led to errors due to folds forming at the pouch neck during sealing. With the new deep-drawing technology, the number of mispackaged items can now be reduced. The placement of products into the packaging can also be automated. The products are inserted into the packaging cavities by multiple robots.

Special film holder for bottom film and Tyvek® strips

The films processed are soft films (mono-PE) with a thickness of approximately 600µ. With the new machine design, a deep draw ratio of up to 14 can be achieved. The R 900 is equipped with a jumbo film feed. For the Tyvek® strip, through which the OP kit is subsequently sterilized, the company has integrated a separate film feed and a separate pre-sealing station into the packaging machine.

The forming station of the R 900 is equipped with a new lifting device with servo drive and a trapezoidal spindle for the forming punch, which optimizes the formation of the packaging cavities. The explosion forming system has also been adapted to provide the large air quantities required for the large packaging cavity.

The sealing and cutting units of the R 900 also feature new servo-driven lifting mechanisms that are particularly energy-efficient and generate a closing force of three tons. Multivac has also integrated a new exhaust collection system into the forming lift mechanism.

The support system with roller conveyor and discharge belt can be adjusted in height via servo motor. The cross-cutting QRP for special materials has been integrated into the cutting system.

Due to the machine height of 1.30 meters, the company has equipped the machines with a special lifting trolley of type HW 201. Thanks to a special side cover in the area of the lifting mechanisms, the doors can be opened more easily. Additionally, a special safety concept with protective shutters at danger points in the loading area and at the outlet has been developed.