Complete Integrated System for Fresh Salad Tray Packaging
The industry-leading solution for high-speed, precise portioning of fresh salad products into retail-ready trays with enhanced presentation and extended shelf life
Complete System Overview
Our advanced lettuce tray packing line represents the latest generation in integrated fresh produce packaging technology. The complete system includes:
- Inclined Conveyor: Gentle elevation of product into the weighing system
- 5L/7L 14-Head Multihead Weigher: Precise portioning with minimal product damage
- Tray Denester: Automated separation and positioning of empty trays
- Filling Station: Accurate deposition of weighed product into trays
- Optional Integration: Compatible with tray sealing, labeling, and secondary packaging systems
Technical Specifications
| Feature | Specification |
|---|---|
| Weight Range | 100-1000g product capacity per tray |
| Maximum Speed | Up to 40 trays per minute |
| Tray Dimensions | Length: 150-300mm, Width: 100-250mm, Height: 30-100mm (Sizes can be customized) |
| Tray Material Compatibility | PP, PET, biodegradable, trays |
| Control System | 10″ Touchscreen HMI with intuitive software |
| Construction Materials | 304 stainless steel, food-grade components |
| Power Requirements | 220V, single phase, 50/60Hz |
| IP Rating | IP65 (washdown protection) |
Key Customer Challenges Addressed
🥬 Product Freshness Preservation System
Our salad tray packing system is specifically engineered to minimize labor requirements while ensuring consistent product quality, addressing the unique challenges of leafy green vegetables packaging with automation that reduces handling steps and increases operational efficiency.
- Gentle Product Handling: Minimizes bruising and damage to delicate salad leaves
- Rapid Processing Cycle: Reduces product exposure time, preserving nutritional value
- Hygienic Design Architecture: IP65-rated components minimize contamination risks
VALIDATED PERFORMANCE: Our tray packing systems operate in numerous commercial salad processing facilities worldwide, consistently reducing labor costs by 60% while maintaining superior product presentation compared to manual tray packing methods.
Key Components & Benefits
1. Inclined Conveyor System
- Variable Speed Control: Optimizes product flow rate to the weigher
- Gentle Incline Profile: Specially designed for salad to prevent tumbling damage
- Food-Grade Belting: Ensures complete food safety compliance
- Quick-Release Belt: Facilitates thorough cleaning and maintenance
2. 5L/7L 14-Head Multihead Weigher
- High-Precision Weighing: Achieves target weights with minimal giveaway (±1.5 grams)
- Anti-Stick Surface Technology: Prevents product adhesion for accurate weighing
- Advanced Weight Combination Algorithm: Ensures optimal weight combinations
- Quick-Release Components: Tool-free disassembly for thorough cleaning
- Memory Storage: Stores up to a full year of weight data for quality assurance
3. Tray Denester
- Multi-Stack Capacity: Holds multiple stacks of empty trays for extended operation
- Precision Separation: Reliably separates individual trays from stacks
- Multi-Format Capability: Handles various tray sizes with minimal changeover time
- Positive Placement System: Ensures trays are perfectly positioned for filling
- Low-Level Alert: Notifies operators when tray supply needs replenishment
- Jam Detection: Automatic detection and alert for any tray feeding issues
4. Filling Station
- Precision Product Placement: Ensures accurate deposition into each tray
- Gentle Product Release: Minimizes drop height to protect product integrity
- Quick-Change Format Parts: Facilitates rapid changeover between tray sizes
Optional System Enhancements
- Automated Tray Sealing Integration: Seamless connection to heat sealing systems
- Metal detector and checkweigher: Ensure the product safety and weight accuracy
- Robotic Case Packing: Complete end-of-line automation
Smartpack offers complete packaging solutions for the fresh produce industry. Get in touch with our experts to talk about your specific needs for rocket salad tray packaging and find out how our integrated solutions can help you make more products, increase the quality of your products, and make them seem better in stores.
Case Study: Fresh Rocket Salad Processor
A major rocket salad producer implemented our tray packing system and achieved:
- 60% reduction in labor costs associated with tray filling
- 4.2% decrease in product giveaway
- 25% increase in overall line efficiency
- Significant improvement in product presentation consistency
- ROI achieved in 14 months
Frequently Asked Questions (FAQ)
Q1: How quickly can the system change between different tray sizes?
A1: Our system features tool-free changeover mechanisms that allow format changes in under 15 minutes. The denester and filling station have quick-adjust components designed specifically for rapid transitions between different tray formats.
Q2: Can the system handle different varieties of salad?
A2: Yes, the system is designed with adjustable parameters for different salad types. The weighing system and transfer components can be optimized for everything from dense iceberg to delicate leaf salad with simple parameter adjustments through the HMI.
Q3: How does the system ensure consistent product presentation in every tray?
A3: Our filling station incorporates a proprietary distribution mechanism that gently guides product into the tray in a consistent pattern. This ensures that each tray has an attractive, retail-ready appearance without manual adjustment.
Q4: What hygiene standards does the machine meet?
A4: The entire system is constructed to IP65 standards with food-grade materials throughout. All product contact surfaces feature tool-free removal for thorough cleaning, and the open-frame design eliminates areas where product debris could accumulate.
Q5: Can the system integrate with our existing tray sealing equipment? A5: Yes, our tray packing system is designed with standard integration points for downstream equipment including tray sealers, labelers, and case packers from all major manufacturers. Our engineering team provides comprehensive integration planning and support.