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Introduction Top Lidder series
There can be various reasons for placing a separate lid or top tray onto a package of trays with eggs. These lids are placed manually or using a so-called top lidder. These top lidders were introduced to the market some time ago.
Moba offers a special Top Lidder series with the following functions:
TL10: For placing top trays on top of trays stacked for palletizing purposes or on top of a single tray for shrink-wrapping trays, including a top tray.
TL20: For placing lids on special consumer packs (so-called ‘tray packs’) with a separate lid.
TL30: For placing top trays on top of trays stacked in a case.
The TL10 explained
The TL10 serves two purposes:
- In combination with tray palletizing
The TL10 is typically positioned between a tray stacker and a tray palletizer, like the MR40. Every stack of six trays passing the TL10 will trigger a top tray to be placed on top of this stack. The purpose is to protect the eggs, as the palletizer places a layer pad (cardboard or wooden plate) between each layer of trays. If that would be placed on top of the eggs, they will be damaged. The top tray will protect the eggs in the upper tray of each stack. This mostly applies to paper trays, since plastic tray systems all have layer pads that protect the eggs without the need of a top tray. The benefit of the system? Without the TL10, manual actions are needed before stacks of trays can be palletized. It therefore enables automatic palletizing of pulp or plastic trays without specialized layer pads. The capacity of the TL10 is approximately 27 top trays per minute. When stacks of 180 eggs are processed, this exceeds the capacity of a tray palletizer by far.
- In combination with shrink wrapping
In many cases, a tray filled with eggs is sold as a ‘consumer pack’. Often a top tray is added and the combination of eggs, sandwiched between two trays, is sent through a shrink-wrapping machine. For this purpose, the TL10 is typically positioned in the Contiflow system just before the shrink wrapper. It can also be placed on the Take-away Conveyor behind the grader, from where the trays are taken away manually. The capacity of the TL10 is 27 top trays per minute. If trays with 30 eggs are processed, the capacity is 48,600 eggs per hour. The benefits are obvious: automating product flows to shrink wrappers at capacities close to 50,000 eggs per hour is impossible for human operators.
The TL20 explained:
Separate covers for trays and inserts have been on the market for a long time. About five years ago, a new combination was introduced. This particular pack can be seen as a large plastic consumer pack where the lid is not attached, as on a regular prepack. The pack is generally known as ‘tray pack’.
The bottom part of the pack is processed on a regular packing lane, just like a tray. The separate lid has to be fitted after the eggs are deposited. If this is done manually, extra staff is required in the packing process behind the grader.
For the automatic application of the lids onto the filled tray, Moba has developed a solution: the TL20 Top Lidder. A stack of lids is placed in a magazine. One lid is de-stacked from the stack and placed and locked onto the plastic tray-part.
The machine is usually fitted onto the end of the packer lane but can also be used on Contiflow. The TL20 is designed in such a way that it can keep up with the maximum capacity of an Omnia packing lane. It is currently capable of handling 3 types of tray packs (20, 24 and 30 egg packs, from various pack suppliers).
The TL30 explained:
Cases filled with trays require an empty tray on top for protection before the box is closed. The TL30 makes it possible to distinguish cases with trays from cases with consumer packs in the case transport system. When it ‘sees’ a case with trays it automatically places a top tray in the case.
The TL30 can handle one type of top tray, while simultaneously handling different case sizes. The TL30 is equipped with a vision system to distinguish cases that require a top tray from those which do not.
In general, the capacity of the TL30 exceeds the capacity of a single casepacker, so multiple casepackers can be integrated with a single TL30. Further on, a dedicated top tray dispenser for cases will not affect the performance of the casepacker. Finally, the TL30 can be located away from the casepackers where there is sufficient room available to place a pallet of top trays.
The TL30 has a single Moba tray denester to singulate top trays from a stack of trays. The stack magazine can easily contain a standard bundle of approximately 120 trays. As an option, a reject conveyor can be added to the system. This enables cases to be diverted from the main case conveyor system in case of an error. It prevents the main case conveyor from coming to a complete stop.
The capacity of the TL30 is 18 half cases or 9 full cases per minute, however cases with consumer packs passing through will have an effect on the capacity.