Moba egg graders are packed with technology. Some designs are worth further investigation as they represent crucial customer value. In this series of articles, we will be zooming in on these "hidden gems". This time, we take a closer look at the abilities of the Moba denester, as used on Omnia and Forta graders as well as farmpackers.
The Moba universal denesters have remained the same for a very long time, and that is not a coincidence. They are still considered to be top of their league, even after an impressive lifecycle of over forty years. The flexible and straightforward setup has proven itself over and over again and will continue to do so in the future.
In packaging handling, it can be said that
denesting is one, if not the most important process when it comes to egg
grading today. This is logical since the denester is the beginning of the
packaging process. If something goes wrong at the start, then the entire
downstream process will suffer from potential delays and possible production loss.
Linked with that is packaging quality and proper setup of the denester. Moba's
setup is so flexible that the denester is capable of processing more than 1,500
First step: isolating a single pack
New packs typically arrive in bundles of about 50–60 pieces, depending on the room between the individual packs. This is exactly where the most important part of the denesting process takes place. The individual distance between packs in a stack can differ per pack type. This means that the separation height for every specific pack can be different. Therefore, the Moba denesters use exchangeable separator sets that are configured exactly for a specific pack. Currently, there are 227 different separator sets in use on our denesters worldwide.
Second step: grab and release the pack
Once the separators have isolated a pack from the stack, the pack is grabbed from the inside by specific grippers. Small needles in the grippers are used to grab the pack firmly from the inside to pull the pack apart from the stack. Again, because there are many different shapes and sizes in egg packaging, the grippers can be positioned exactly in the correct position. This can be done in two horizontal dimensions. The exact position is described in specific coordinates that, again, can be different for every pack. The grippers pull the pack down and release it onto the transport strings in the denester.
Third step: transport
As soon as the pack has been released successfully, the transport strings take over the process and release the pack into the pin conveyor. The transport section can also be adjusted according to the specific dimensions of the pack. The strings are constructed in such a way that they can absorb the energy from the momentum the pack has received during the pull-down. The transport strings themselves can be mounted in a high and a low position, where the low position provides a bit more room for the pack to travel through. This setup is recommended when consumer packs are processed with a large front.
The universal denester is capable of handling most egg packaging used in the egg grading business, but there are a few exceptions to the rule. Some pack types are so specific that special attention is required.
In the Far East, a range of consumer packs is
used that is stacked so tight together that our separation sets are not capable
of getting in between to isolate a single pack. Also, grabbing this pack with
our standard grippers is quite challenging due to the shape of the packs and
the fact that they are very smooth. For this, a vacuum denester is available,
which can be mounted on the pin conveyor. This denester uses one or two vacuum
cups to grab the pack(s) and separate them from the stack before the pack is
released in the pin conveyor. After the pack is released, it will be processed
in the same way as any other consumer pack.
Large consumer pack denesters
In several regions of the world, consumer packs are bigger than your standard 10-, 12- and 18-egg packs. A 24-egg pack can still be handled by a standard denester, but once the consumer pack has over four rows (e.g. 30 or 36 eggs), it becomes too large to be handled by a standard denester. To process these Large Consumer Packs (LCP), an extended denester is available. This denester can be used to process consumer packs from three to six rows long, as well as standard 30-egg trays. However, this denester operates only in combination with a special pin conveyor and a dedicated LCP-packing lane.
Plastic tray denesters
Plastic trays have been specifically designed to be re-used many times. In between uses, the trays are washed and sent out to be re-used to collect eggs from the farm. Collecting eggs using a Mopack farmpacker requires the denester to handle a larger stack of trays in the hopper. Due to the weight of such a stack, some modifications have been made to reduce extra wear and to avoid excess strain on the moving parts. Also, plastic trays are known to stick together quite firmly from time to time for various reasons. This causes issues in the first and second steps of the denesting process. For this reason, the grippers pulling the single tray down are more rigid for a much better grip. This specific denester is therefore far less sensitive to handling errors and improves the overall efficiency of farmpacking. To even further increase the number of trays to the denester, an automatic denester filler with a supply conveyor can be added to this denester.
If you want to know more about Moba's denesters, please contact your local sales representative.