Advanced Integrated Packaging Line for Fresh Lettuce Products
The industry-leading solution for high-speed, precise packaging of fresh lettuce products with extended shelf life. Smartpack has a lettuce packing machine for pillow bags. No matter how big or small your workshop is, Smartpack can help you find the ideal solution.
Key Customer Challenges Addressed
🥬 Product Freshness Preservation System
Our lettuce packaging system is specifically designed to keep the product as fresh as possible during the packing process, which is important because leafy green vegetables have their own set of problems.
- Gentle Handling Technology: Minimizes bruising and damage to delicate lettuce leaves
- Rapid Processing Speed: Reduces time from harvest to package, preserving nutritional value
- Cross-Contamination Prevention: Hygienic design minimizes food safety risks
VALIDATED PERFORMANCE: Our packaging solutions are used in many fresh produce plants throughout the world, and they always generate better quality products that last longer than traditional packaging methods.
🌱 Lettuce Product Integrity Protection
Our technology features specialized protection systems developed specifically for fragile leafy greens:
- Minimal Contact Points: Reduces bruising and mechanical damage
- Smooth Transfer Transitions: Prevents leaf breakage during product movement
- Customizable Weighing Parameters: Adapts to different lettuce varieties and conditions
- Precise Weight Control: Minimizes giveaway while ensuring regulatory compliance
Complete System Overview
Smartpack’s lettuce packaging 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
- Vertical Form Fill Seal Machine: Form perfect pillow bags with consistent sealing from the roll film
- Output Conveyor: Smooth transfer of finished packages
- Rotary Collection Table: Efficient package collection for secondary packaging
Technical Specifications
| Feature | Specification |
|---|---|
| Weight Range | 100-1000g product capacity |
| Maximum Speed | Up to 60 packages per minute |
| Bag Dimensions | Length: 150-350mm, Width: 100-250mm |
| Film Compatibility | Laminted film, single layer film, biodegradable films |
| Control System | 10″ Touchscreen HMI with intuitive software |
| Construction Materials | 304 stainless steel, food-grade components |
| Power Requirements | 220V, single phase, 50/60Hz |
| Air Requirements | 0.6-0.8MPa, 0.1m³/min |
| IP Rating | IP65 (washdown protection) |
Key Components & Benefits
1. Inclined Conveyor System
- Adjustable Speed Control: Optimizes product flow to the weigher
- Gentle Incline Angle: Prevents product damage during elevation
- Food-Grade Belting: Ensures food safety compliance
- Quick-Release Design: Facilitates thorough cleaning and maintenance
2. 5L/7L 14-Head Multihead Weigher
- High-Speed Processing: Achieves target weights with minimal giveaway
- Gentle Bucket Design: Custom-shaped buckets for lettuce handling
- Anti-Stick Surfaces: Prevents product adhesion and ensures accurate weighing
- Easy Cleaning Design: Tool-free disassembly of contact parts
3. Vertical Form Fill Seal Machine (VFFS)
- Precise Bag Formation: Creates consistent pillow bags with perfect seals
- High-Speed Operation: Maximizes production efficiency
- Gas Flushing Capability: Optional device extends product shelf life
- Film Management System: Minimizes film waste and ensures proper tension
- Date/Lot Coding Integration: Prints essential traceability information
4. Output Conveyor
- Smooth Transfer Design: Prevents package damage
- Adjustable Speed Control: Synchronizes with packaging rate
5. Rotary Collection Table
- Accumulation Capacity: Provides buffer for secondary packaging operations
- Gentle Rotation Speed: Prevents package damage
- Ergonomic Height: Reduces operator fatigue
- Stainless Steel Construction: Ensures durability and cleanliness
- Simple Operation: Minimizes training requirements
Case Study: Major Fresh Produce Supplier
A lettuce supplier implemented our complete packaging system and achieved:
- 35% increase in packaging line efficiency
- 3.2% reduction in product giveaway
- 2-day extension in product shelf life
- 40% reduction in labor costs
Production Efficiency Benefits
- Reduced Labor Requirements: Automates previously manual processes
- Consistent Package Quality: Eliminates variations in package appearance
- Precise Weight Control: Typically reduces giveaway by 2-4% compared to manual operations
- Increased Throughput: Achieves up to 60 packages per minute
- Extended Product Shelf Life: Faster packaging preserves freshness
- Quick Changeover: Format changes in under 15 minutes
- Reduced Downtime: Robust construction and reliable components
User-Friendly Operation
- Intuitive HMI Interface: Simple touchscreen operation
- Recipe Storage: Quick recall of product settings
- Multilingual Support: Available in multiple languages
- Remote Diagnostics: Optional connectivity for technical support
- Comprehensive Training: Included with system installation
Frequently Asked Questions (FAQ)
Q1: How does the system handle different lettuce varieties?
A1: Our system includes adjustable parameters for different lettuce types. The multihead weigher buckets are designed to handle everything from iceberg to delicate leaf lettuce, with easily adjustable settings for optimal handling of each variety.
Q2: What cleaning procedures are required for the system?
A2: All product contact surfaces feature tool-free removal for thorough cleaning. The system is designed to IP65 standards, allowing washdown cleaning. A complete sanitation cycle typically requires 45-60 minutes.
Q3: Can the system integrate with our existing production line?
A3: Yes, our modular design allows seamless integration with existing conveying, cooling, and secondary packaging equipment. Our engineering team provides comprehensive integration planning and support.
Q4: How accurate is the weighing system for lightweight lettuce products?
A4: Our multihead weigher achieves accuracy within ±1% of target weight, even for lightweight applications. The specialized 5L/7L configuration is specifically optimized for lightweight, bulky products like lettuce.
Q5: What maintenance is required to ensure optimal performance?
A5: The system requires standard preventive maintenance including daily cleaning of product contact surfaces, weekly inspection of sealing components, and monthly verification of weigher calibration. Complete service documentation is provided with the system.