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Single-packed Product Reclamation

Automated, High-speed Recovery of Unsalable, Single-packed Product and Packaging

NBE single-pack reclamation systems provide brand owners and contract packagers automated, adaptable, and effective methods for recovering contents and packaging when upstream factors result in off-spec, mis-labeled, over-run, or unsalable packs. From stick packs, sachets, or gusseted packs to pouches or pillow packs; from food and beverage, pharma, or personal care products to household or commercial products, NBE single-pack reclaim systems safely reduce product and packaging material waste. NBE single-pack reclamation systems are engineered-to-application (ETA) based on unique functional requirements, automation specifications, and effectiveness measures of the application.

Application Selections

Material loss reduction is just one of the multiple advantages realized from NBE single-pack product reclaim systems. NBE engineered-to-application project execution advances the design and production of NBE reclaim systems beyond the common limitations inherent to off-the-shelf equipment. NBE single-pack reclaim systems deliver total process performance, and long-term reliability regardless of challenging product characteristics or difficult packaging materials.

Manual Package Infeed

When product reclamation and package recovery events periodically occur, or when frequent reclamation events occur with fewer packs, this NBE single-pack reclamation system reduces the risks and increases the reclaim yield relative to hand rework methods.

  • Package Infeed, Horizontal Conveyor: Controlled by a variable frequency drive, the infeed conveyor meters the supply of packs into the package opener. Operators need only load packs onto the staging table and move packs from the table onto the conveyor feed belts. Eliminate operator use of razor knives, reduce batch run times, and increase product reclamation yield.
  • Package Opener: Conveyor feed belts safely move packs into the package opener where high-speed, beveled-edge rotating blades precisely cut through the packs to enable packaged contents to be released. Application-specific design, and high-speed rotation of the blades minimize the introduction to the product stream of packaging material fines.
  • Rotary Separator: Opened packs from the package opener fall directly into the rotary separator. Tumbling action of the rotary separator drum removes contents from the opened packs. Angled flights in the separator drum ensure thorough material release from the packs and draw the empty packs out of the drum. Reclaimed contents are screened through the separator drum and collected in the reclaim hopper. Emptied packaging material is discharged from the rotary separator and collected for recycling.
  • Recovered Packaging Handling: Emptied and separated from the reclaimed contents, the recovered product packaging sections are automatically discharged from the rotary separator into a screw compactor. The collected packaging scrap is packed and prepared for recycling.
  • Dust Collection: Packaged product, and packaging material itself, can create dust during the reclamation and recovery process. Collection, filtration, and reintroduction to the product stream of dusted product further reduces material loss. Collecting and filtering product and packaging dust from workplace air protects labor from airborne dusts and reduces facility and equipment maintenance.

Automated Package Infeed

When product reclamation events require processing rates not feasible by manual infeed, or when pack types cannot be efficiently processed manually, the NBE automated package infeed system provides a consistent, high-rate supply of packs; even packs of challenging size, material type, and construction.

  • Infeed Conveyor Loading System, Container Dischargers: Upstream process factors, such as: collection methods for reject packaged product, frequency of production reject events, and the volume of reject product generated per event, can all lead to the need for application-specific loading systems. NBE conveyor loading systems work to safeguard operators from container lifting and repetitive movement strain and can also simplify process integration between packaging equipment and reclamation systems.
  • Package Infeed, Incline Conveyor: Packages being processed for reclamation and recovery are automatically fed by the incline conveyor to the package opener. Optimal run rate for the reclamation and recovery sequence is controlled by the variable frequency drive of the incline conveyor. Application-specific engineering of the conveyor framework, together with proper conveyor belt design and materials of construction, ensure reliable process performance while operators are kept safely away from the package opener infeed.
  • Package Opener: Fed by the package infeed conveyor, this automated package opening system eliminates labor re-allocation, reduced speed, and risk of injury common with manual package opening methods. Engineered to application specifications for package shape, size, and process feed volume; the high-speed, beveled-edge rotating blade sets of the package opener are vertically or horizontally oriented to ensure all packs are opened prior to recovery.
  • Rotary Separator: Opened packs from the package opener fall directly into the rotary separator. Tumbling action of the rotary separator drum removes contents from the opened packs. Angled flights in the separator drum ensure thorough material release from the packs and draw the empty packs out of the drum. Reclaimed contents are screened through the separator drum and collected in the reclaim hopper. Emptied packaging material is discharged from the rotary separator and collected for recycling.
  • Reclaimed Product Takeaway: Removed and separated from its package, the reclaimed contents are collected into the product reclaim hopper. Based on downstream product supply requirements, NBE will design, engineer, and integrate process-specific mechanical systems and automation, including: screw conveyors, bi-directional screw conveyors, belt conveyors, bucket elevators, or pneumatic conveying.
  • Recovered Packaging Handling: Emptied and separated from the reclaimed contents, the recovered product packaging sections are automatically discharged from the rotary separator into a screw compactor. The collected packaging scrap is packed and prepared for recycling.
  • Dust Collection: Packaged product, and packaging material itself, can create dust during the reclamation and recovery process. Collection, filtration, and reintroduction to the product stream of dusted product further reduces material loss. Collecting and filtering product and packaging dust from workplace air protects labor from airborne dusts and reduces facility and equipment maintenance.
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