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TR brochure





TABLE OF CONTENTS

OVERVIEW-----------------------------------------------------------------------------------------3
o
The POLYPACK Tray Loader/Former Series (TR)


PRODUCT COLLATION: Lane Dividing Options----------------------------------------------4
o
Dead Plate
o
Flood Feed
o
Oscillating Diverter


PRODUCT COLLATION: Creating Multi-Packs-----------------------------------------------5
o
Staging Mechanism
o
Flight Bar Conveyor
o
Tray Blank Magazine
o
Tray Folding


TRAY FORMING: Folding Tray Flaps-----------------------------------------------------------7
o
Tray Folding Lugs
o
Small Flap Tucking
o
Hot Melt Applicator


ADJUSTMENTS: Automatic & Mechanical----------------------------------------------------8
o
Automatic & Mechanical


GENERAL CONSTRUCTION---------------------------------------------------------------------9
o
Interlocked Safety Doors
o
Self Monitoring Diagnostics
o
Standard Features


EQUIPMENT SPECIFICATIONS---------------------------------------------------------------10


AFTER SALES SUPPORT-----------------------------------------------------------------------11
o
Warranty
o
TR Series Models
o
Options


COMPANY INFORMATION---------------------------------------------------------------------12
o
Equipment
o
Corporate Headquarters


OVERVIEW
The POLYPACK Tray Loader/Formers: TR-35 & TR-50

Polypack manufactures an entire series of automatic product collating, tray loading,
tray forming and shrink systems.
TR series machines are extremely versatile, easy to operate and highly reliable. They
accept products, automatically divide them into multiple lanes, index the laned
products and isolate them to create multi-packs. Products are positively controlled
throughout the collating/traying process. Adjustments for different tray sizes are made
quickly and easily (less than 10 minutes changeovers!). TR machines can be integrated
with a Polypack shrink wrapper to provide a secure, protected package ready for
distribution or retail sale.

Method of Operation
Individual products will arrive automatically, single file, where they will then be divided
into multiple lanes. A dead plate is used to divide round products into two or four
lanes. A flood feed system is used for a more versatile division of round products into
two, three, four, five or six lanes. The combination of square/rectangular and/or round
products can be divided into two, three, four, five, or six lanes using an oscillating
diverter.

After the products are divided into lanes, a staging mechanism will form the desired
pack pattern. A flight bar conveyor will transfer the products together after the gate
releases them along the conveyor. The flight bar conveyor will move the products onto a
pre-dispensed corrugated tray blank.

The tray folding lugs located underneath the tray flaps will fold the front and back tray
flaps up against the products. The small flap tucking system will fold the small flaps
against the products. The hot melt applicator will apply adhesive to the four corners of
the side tray flaps. The guides will then fold up the side flaps. As the tray exits, it will
be compressed by rollers to allow the hot melt to dry.







TR-35 & TR-50
Page 3
05/06 2. Flood Feed: divides round products into
two, three, four, five or six lanes.

Our flood feed conveyor allows products to
accumulate in front of an oscillating lane
diverter. Individual lanes can be opened or
closed off to control the number of lanes
being loaded with product.


PRODUCT COLLATION: Lane Dividing Options
1. Dead Plate: divides round products
into two or four lanes.

Polypacks dead plate dividers use
accumulated product back-pressure to
divide product from one lane to two
lanes.
The divider parts are fixed. The process
can be repeated for each lane, further
dividing the products into four lanes.
Dead plate dividers are fixed assemblies.
They do not use moving parts and do not
involve adjustments.

3. Oscillating Diverter: divides round or
square/rectangular products into two, three,
four, five or six lanes.

Polypacks oscillating divider feeds products
into multiple lanes:
1. products accumulate in the diverter
2. the diverter moves in front of a lane
3. product is released into that lane
4. the diverter moves the fill product into
adjacent lanes.

TR-35 & TR-50
Page 4
05/06

PRODUCT COLLATION: Creating Multi-Packs
Staging Mechanism
Product is accumulate behind gates in
each lane of the TR machine. An
adjustable clamp is positioned so that the
correct number of products (number of
rows) for each tray is positioned between
the gate and the clamp. The clamp holds
back the accumulated product, while the
gates open to release the correct number
of products to fill a tray.












Fight Bar Conveyor
As products are released from the
gates, a flight bar moves down
between the product group. A set of
automatically adjusted lane guides brings
the lanes of product together as the flight
bar moves product across a dead plate.
The dead plate ends, and the flight bars
loads products onto the mechanically
positioned and synchronized tray blank.

ADJUSTABLE
CLAMP
FLIGHT BARS
LOAD PRODUCT
(moving product
across dead plate)
PRODUCT RELEASED
FROM GATE
(between flight bars)
TR-35 & TR-50
Page 5
05/06
GATES TRAYS ARE FORMED
AROUND THE PRODUCTS
VERTICAL TRAY
BLANKS MAGA-
PICK & PLACE
SYSTEM


PRODUCT COLLATION: Creating Multi-Packs
Tray Blank Magazine
A vertical or optional larger-capacity
horizontal tray blank magazine holds
trays blanks.
Polypacks pick and place system moves
one tray blank at a time onto a motor
driven lug conveyor.












Tray Folding
The flight bars and the tray blank lug
conveyor are mechanically synchronized to
ensure the product and the tray blank are
positioned correctly every time.
The lug conveyor moves tray blanks under
the dead plate that the flight bars are
moving the products across.

The dead plate ends, and the flight bars
loads product onto the tray blank.
The tray is tightly formed against the
collated product. Properly formed and sized
trays reduce product vibration and label
scuffing.

FLIGHT BARS
LOAD PRODUCT
(end of dead plate)
TR-35 & TR-50
Page 6
05/06
TRAY MAGAZINE
(vertical or optional
horizontal)
PICK & PLACE
TRAY DELIVERY

TRAY FORMING: Folding Tray Flaps
Tray Folding Lugs
When product is on the tray blank,
the tray folding lugs pop up from
underneath the tray blank and fold
the front and back tray flaps
up-against the product. A set of
rollers above the products can be used
to hold down and stabilize lightweight
products during this process.

Small Flap Tucking
The leading edge left and right small
flaps are folded back against the
products by a set of stationary guides.
The trailing left and right small flaps
are folded forward by two stepper
motor controlled paddle wheels.

Hot Melt Applicator
A high quality Nordson
®
ProBlue hot
melt system applies two beads of hot
melt to each of the four corners of the
side tray flaps.

The side flaps are folded up against
the product, securing the holt melt
against each of the four small corner
flaps.

With the tray forming, gluing process
complete, the completed trays travel
through a set of side compression
rollers to allow the hot melt time to set
up and dry.
SIDE COMPRESSION
ROLLERS
HOT MELT
APPLICATOR
TR-35 & TR-50
Page 7
05/06
TOP COMPRESSION
ROLLERS
(as required)
SMALL FLAP
TUCKING
FRONT AND REAR
FLAP FOLDING

ADJUSTMENTS: Automatic & Mechanical




Acme Screw Adjustments
Major components are adjusted automatically via the color touch screen.
Other components require simple tool-free adjustment.

Lane Adjustments
The number of lanes is adjusted manually. The width of each lane is
adjusted automatically (fan effect, where all the lanes adjust together).


Row