Lyons Magnus is located in Fresno, California. The company was founded in 1852 and was the first company to package fruit products on the 10th tank. Afterwards, it first took the lead in the development of fruit aseptic processing and packaging technology – until now, the company This solution is still available for food ingredients customers.
In the 1990s, Lyons was also the first American company to use the SIG Combibloc large-scale filler to aseptically fill more than one litre beverage cartons. This third-generation filling system not only improves Lyons' productivity, but also maximizes the flexibility of the carton used.
The pioneer of aseptic technology
The history of Lyon Magnus can be traced back 150 years. The company's first product was pomegranate pulp. Today, the company has experienced several mergers and acquisitions and large-scale expansion, and already has three operating departments. Lyons Food Services offers catering operators a wide range of products, including soda syrup, sterile juices, beverage bases, fruit fillings and breakfast ingredients; the Seasoning Department provides customers with frozen desserts, lactic fermentation products or beverages The product's fruit and flavor preparations; Lyons's International Catering Ingredients company specializes in providing product taste, functionality, and packaging services to customers outside the United States.
Lyons processes and packs catering and food ingredients for his own brand, and also specializes in the processing and packaging of specialty brand products for major catering companies. Lyons entered the aseptic packaging market more than a decade ago, said Robert Smittcamp, president of Lyons Magnus. At the time, most US users thought that the packaging was just the kind of boxed children's juice that was introduced in the early 1980s. The cold storage system in the United States is far more developed than in Europe. Therefore, Americans are not interested in retail aseptic packaging milk, although this product has long been popular in European countries.
But Lyons recognizes that providing aseptic processing and packaging with greater capacity for catering services brings many benefits, including: higher sterility, retention of product flavor and appearance, longer shelf life, and repeatability (For some kinds of products). In addition, sterile products are easy to store, saving valuable space occupied by refrigeration equipment and eliminating the need for time-consuming thawing. The carton is designed to have a square shape and high space utilization; with a semi-rigid structure, it can be flattened. SIG said: "Spam can occupy up to 90% less space."
Since Lyons's installation of the first Combibloc CF 405-11 liquid filling system in the Fresno factory in the 1990s, the company’s production needs have continued to grow and an aseptic filling system has been added. In 1997, CF 405-AF pelletizer was purchased. By the end of 2004, Lyons had replaced the original Combi filling machine with CFA 406-32 equipment. This is a cb4 filling machine. According to SIG Combibloc, this means that the machine can use bottom-standard (114 × 74mm), high-height cartons to produce capacities of 1 liter, 1.5 liter and 2 liter. package of. Steven Taylor, vice president of sales and service at SIG Combibloc, said: "In the United States, we have a special size of 46 and 64 ounces, which is specifically developed for the catering service market."
Lyons uses the CFA 406-32 device to fill approximately 300 different products from water to chocolate. These products have different viscosities and can use 46-ounce, 64-ounce, and 1-liter cartons. Compared with the replaced machine, the new filling machine can achieve a speed of 6,000 boxes per hour, which is 1,000 more than the old one.
The production of the box body is airtight
Other aseptic packaging processes perform vertical forming/filling/sealing operations on rolls of raw materials. The solution used by SIG Combibloc is to process pre-made boxes with horizontal devices. According to SIG, the use of pre-made cartridges improves the quality of the final product because a special longitudinal seam sealing process guarantees that the product does not come into contact with any uncoated edges during the filling process. .
The pre-molded boxes are machined by SIG Europe Packaging, which produces more than 10 billion cartridges annually. The combi carton consists of cardboard, polyethylene and aluminum. 75% of the paperboard is made of fibrous material, which is coated with polyethylene on the inside and outside, so that the paper box will not leak. In order to prevent light and prevent oxygen from infiltrating, an ultra-thin aluminum layer is added, and then a layer of polyethylene is applied to bond the aluminum layer to the cardboard. Afterwards, the finished cardboard is gravure-printed in up to five colors. Cut the cardboard to the required size according to different combo packaging formats. Lyons Magnus' latest machine, the Combibloc Max, is designed for high-capacity filling on CFA 406-32 equipment.
Next, the carton blanks are creased and ready for subsequent folding. The final stage is longitudinal seam sealing.
In the "sterilized zone" of the machine, the sterile air is electrically heated, blown into an empty box several times, and the hydrogen peroxide that was previously poured into the box to kill microorganisms is blown dry.
Filling assures sterility
The new aseptic filling system runs on Lyons and has a magazine that can hold 2,000 cartons. Manually loading the printed rolls into the magazine and positioning them laterally by vibrating to facilitate future operation. separate. In an interview with PD Magazine, Lyons Magnus is filling a 48-ounce cartons of concentrated orange juice, which is a vendor’s own brand. The carton is printed in blue with several white areas above it for coding and product labelling.
The suction device separates each paper tube from the material warehouse, and arranges it into a rectangular shape and slides it onto the top bar to ensure the correct positioning of the bottom of the package. Afterwards, hot air was blown to the bottom of the two tables to prepare for sealing. The ejector wheel conveys the paper tube to the press bottom table, and the lateral rotary folding machine and the longitudinal folding machine pre-fold the bottom surface into a special double-folded form to ensure that no uncoated paper surface is exposed at the bottom of the package. The bottom die of the box and the top surface of the top bar act together to press the bottom of the box and seal it.
After this, the carton is removed from the top bar, pushed into a pocket and passed through the rest of the machine, and the box top crease is prefolded. The empty box enters the "sterilization zone" and the hydrogen peroxide and air mixture is heated in the evaporator and blown into the box to kill the microorganisms and disinfect the carton. Next, the sterile air is heated electrically, blown into the box several times, and hydrogen peroxide is blown dry. The hydrogen peroxide is decomposed into hydrogen and oxygen.
The filling station injects the product into the carton in two steps to ensure accurate filling capacity. Before the product is injected into the carton, ultra-high-temperature transient (UHT) disinfection is required: rapid heating to around 130 degrees Celsius and rapid cooling. After the tray is full, when the top of the box is folded and ultrasonically sealed, steam is injected into the box to reduce headspace. Next, the hot air heats the flaps and sides of the carton and forms the top of the box. The box top flap is pressed down and sealed to the carton. The conveyor then sends the filled tray away from the machine.
The full functionality of the filling machine is monitored by the Siemens S7 programmable controller in the system. The programmable controller is equipped with a proprietary operating interface developed by SIG Combibloc. The operator operates the machine functions via an indexed control panel with a color touch screen. The most important machine functions can be controlled via the control panel at the hopper.
The front of the aseptic filling machine has a magazine that can hold 2,000 printed paper tubes. This is the cartridge body. The suction device pulls the single paper cylinder into the machine.
Filling, labeling, and packing cartons
A six-cartridge tray that has already been loaded is waiting for the package at the pallet packer.
After filling, code the carton with the Videojet () Excel 170i inkjet printer. The carton is then transported to the Hartness (1500) vertical collector and sent to the SIG allCap Camby CTL 8000 capper.
To facilitate the capping operation, use a laser to cut the opening of the carton when processing the preformed box. When the mouth is installed, the top of the carton is heated and ready to be glued. The mouth of the box is fed into the production line through the feed rails, and then it is put on the pliers. The Nordson() rubber roller is used to coat the Nordson 3400 series rubber and then pressed into the carton. On the opening cut in advance with a laser. The various functions of the machine are controlled by a programmable controller manufactured by Moeller Electric (), formerly known as Klækner-Moeller.
Before the machine leaves the machine, the SICK () video inspection camera checks the lid and lid. If there is a problem with the lid, a scrap function will be triggered and the problem cartons will be removed from the packaging line.
Lyons bagged ready-to-eat products, fruit juice concentrates and fruit desserts are all re-sealable 28mm combiTwist polypropylene caps. This screw cap was produced in Switzerland by the SIG allCap company. When twisted, a wedge was inserted into a carton that was pre-punched. The seal on the lid can act as an anti-theft feature.
After the carton is inspected with the lid, it is immediately sent to the Accraply () Model 350P step-drive high-speed labeler, which uses labels up to 9 inches wide. The labeler affixes a pressure-sensitive label with product information and barcodes to the front of the box.
Finally, the labeled carton is packaged with a Barry Wehmiller/Zepf () 4000 tray packer. The device uses a lane divider for three operations and is controlled by an Allen-Bradley () SLC 5/04 programmable controller. Tray packers add partitions, which provide additional support for the packaging trays during transport. Lyons' sterile products use two sizes of trays: 6 and 12 boxes. Partitions are only used for 12-pack trays.
A six-cartridge tray that has already been loaded is waiting for the package at the pallet packer.
Product switching time is short In addition to increased productivity, the Conma CFA 406-32 device also brings some additional benefits to Lyons Magnus. The carton size is an example: Lyons uses Combi equipment to fill three sizes with a single machine .
Switching from one package size to another is also quick and easy. According to Robert Smith, on-site engineering supervisor at SIG Combibloc, switching from one carton size to another takes only eight or nine minutes, and the speed of product switching depends on the product itself. He said: "If you switch from fruit juice to chocolate,
In the 1990s, Lyons was also the first American company to use the SIG Combibloc large-scale filler to aseptically fill more than one litre beverage cartons. This third-generation filling system not only improves Lyons' productivity, but also maximizes the flexibility of the carton used.
The history of Lyon Magnus can be traced back 150 years. The company's first product was pomegranate pulp. Today, the company has experienced several mergers and acquisitions and large-scale expansion, and already has three operating departments. Lyons Food Services offers catering operators a wide range of products, including soda syrup, sterile juices, beverage bases, fruit fillings and breakfast ingredients; the Seasoning Department provides customers with frozen desserts, lactic fermentation products or beverages The product's fruit and flavor preparations; Lyons's International Catering Ingredients company specializes in providing product taste, functionality, and packaging services to customers outside the United States.
Lyons processes and packs catering and food ingredients for his own brand, and also specializes in the processing and packaging of specialty brand products for major catering companies. Lyons entered the aseptic packaging market more than a decade ago, said Robert Smittcamp, president of Lyons Magnus. At the time, most US users thought that the packaging was just the kind of boxed children's juice that was introduced in the early 1980s. The cold storage system in the United States is far more developed than in Europe. Therefore, Americans are not interested in retail aseptic packaging milk, although this product has long been popular in European countries.
But Lyons recognizes that providing aseptic processing and packaging with greater capacity for catering services brings many benefits, including: higher sterility, retention of product flavor and appearance, longer shelf life, and repeatability (For some kinds of products). In addition, sterile products are easy to store, saving valuable space occupied by refrigeration equipment and eliminating the need for time-consuming thawing. The carton is designed to have a square shape and high space utilization; with a semi-rigid structure, it can be flattened. SIG said: "Spam can occupy up to 90% less space."
Since Lyons's installation of the first Combibloc CF 405-11 liquid filling system in the Fresno factory in the 1990s, the company’s production needs have continued to grow and an aseptic filling system has been added. In 1997, CF 405-AF pelletizer was purchased. By the end of 2004, Lyons had replaced the original Combi filling machine with CFA 406-32 equipment. This is a cb4 filling machine. According to SIG Combibloc, this means that the machine can use bottom-standard (114 × 74mm), high-height cartons to produce capacities of 1 liter, 1.5 liter and 2 liter. package of. Steven Taylor, vice president of sales and service at SIG Combibloc, said: "In the United States, we have a special size of 46 and 64 ounces, which is specifically developed for the catering service market."
Lyons uses the CFA 406-32 device to fill approximately 300 different products from water to chocolate. These products have different viscosities and can use 46-ounce, 64-ounce, and 1-liter cartons. Compared with the replaced machine, the new filling machine can achieve a speed of 6,000 boxes per hour, which is 1,000 more than the old one.
The production of the box body is airtight
Other aseptic packaging processes perform vertical forming/filling/sealing operations on rolls of raw materials. The solution used by SIG Combibloc is to process pre-made boxes with horizontal devices. According to SIG, the use of pre-made cartridges improves the quality of the final product because a special longitudinal seam sealing process guarantees that the product does not come into contact with any uncoated edges during the filling process. .
The pre-molded boxes are machined by SIG Europe Packaging, which produces more than 10 billion cartridges annually. The combi carton consists of cardboard, polyethylene and aluminum. 75% of the paperboard is made of fibrous material, which is coated with polyethylene on the inside and outside, so that the paper box will not leak. In order to prevent light and prevent oxygen from infiltrating, an ultra-thin aluminum layer is added, and then a layer of polyethylene is applied to bond the aluminum layer to the cardboard. Afterwards, the finished cardboard is gravure-printed in up to five colors. Cut the cardboard to the required size according to different combo packaging formats. Lyons Magnus' latest machine, the Combibloc Max, is designed for high-capacity filling on CFA 406-32 equipment.
Next, the carton blanks are creased and ready for subsequent folding. The final stage is longitudinal seam sealing.
In the "sterilized zone" of the machine, the sterile air is electrically heated, blown into an empty box several times, and the hydrogen peroxide that was previously poured into the box to kill microorganisms is blown dry.
Filling assures sterility
The new aseptic filling system runs on Lyons and has a magazine that can hold 2,000 cartons. Manually loading the printed rolls into the magazine and positioning them laterally by vibrating to facilitate future operation. separate. In an interview with PD Magazine, Lyons Magnus is filling a 48-ounce cartons of concentrated orange juice, which is a vendor’s own brand. The carton is printed in blue with several white areas above it for coding and product labelling.
The suction device separates each paper tube from the material warehouse, and arranges it into a rectangular shape and slides it onto the top bar to ensure the correct positioning of the bottom of the package. Afterwards, hot air was blown to the bottom of the two tables to prepare for sealing. The ejector wheel conveys the paper tube to the press bottom table, and the lateral rotary folding machine and the longitudinal folding machine pre-fold the bottom surface into a special double-folded form to ensure that no uncoated paper surface is exposed at the bottom of the package. The bottom die of the box and the top surface of the top bar act together to press the bottom of the box and seal it.
After this, the carton is removed from the top bar, pushed into a pocket and passed through the rest of the machine, and the box top crease is prefolded. The empty box enters the "sterilization zone" and the hydrogen peroxide and air mixture is heated in the evaporator and blown into the box to kill the microorganisms and disinfect the carton. Next, the sterile air is heated electrically, blown into the box several times, and hydrogen peroxide is blown dry. The hydrogen peroxide is decomposed into hydrogen and oxygen.
The filling station injects the product into the carton in two steps to ensure accurate filling capacity. Before the product is injected into the carton, ultra-high-temperature transient (UHT) disinfection is required: rapid heating to around 130 degrees Celsius and rapid cooling. After the tray is full, when the top of the box is folded and ultrasonically sealed, steam is injected into the box to reduce headspace. Next, the hot air heats the flaps and sides of the carton and forms the top of the box. The box top flap is pressed down and sealed to the carton. The conveyor then sends the filled tray away from the machine.
The full functionality of the filling machine is monitored by the Siemens S7 programmable controller in the system. The programmable controller is equipped with a proprietary operating interface developed by SIG Combibloc. The operator operates the machine functions via an indexed control panel with a color touch screen. The most important machine functions can be controlled via the control panel at the hopper.
The front of the aseptic filling machine has a magazine that can hold 2,000 printed paper tubes. This is the cartridge body. The suction device pulls the single paper cylinder into the machine.
Filling, labeling, and packing cartons
A six-cartridge tray that has already been loaded is waiting for the package at the pallet packer.
After filling, code the carton with the Videojet () Excel 170i inkjet printer. The carton is then transported to the Hartness (1500) vertical collector and sent to the SIG allCap Camby CTL 8000 capper.
To facilitate the capping operation, use a laser to cut the opening of the carton when processing the preformed box. When the mouth is installed, the top of the carton is heated and ready to be glued. The mouth of the box is fed into the production line through the feed rails, and then it is put on the pliers. The Nordson() rubber roller is used to coat the Nordson 3400 series rubber and then pressed into the carton. On the opening cut in advance with a laser. The various functions of the machine are controlled by a programmable controller manufactured by Moeller Electric (), formerly known as Klækner-Moeller.
Before the machine leaves the machine, the SICK () video inspection camera checks the lid and lid. If there is a problem with the lid, a scrap function will be triggered and the problem cartons will be removed from the packaging line.
Lyons bagged ready-to-eat products, fruit juice concentrates and fruit desserts are all re-sealable 28mm combiTwist polypropylene caps. This screw cap was produced in Switzerland by the SIG allCap company. When twisted, a wedge was inserted into a carton that was pre-punched. The seal on the lid can act as an anti-theft feature.
After the carton is inspected with the lid, it is immediately sent to the Accraply () Model 350P step-drive high-speed labeler, which uses labels up to 9 inches wide. The labeler affixes a pressure-sensitive label with product information and barcodes to the front of the box.
Finally, the labeled carton is packaged with a Barry Wehmiller/Zepf () 4000 tray packer. The device uses a lane divider for three operations and is controlled by an Allen-Bradley () SLC 5/04 programmable controller. Tray packers add partitions, which provide additional support for the packaging trays during transport. Lyons' sterile products use two sizes of trays: 6 and 12 boxes. Partitions are only used for 12-pack trays.
A six-cartridge tray that has already been loaded is waiting for the package at the pallet packer.
Product switching time is short In addition to increased productivity, the Conma CFA 406-32 device also brings some additional benefits to Lyons Magnus. The carton size is an example: Lyons uses Combi equipment to fill three sizes with a single machine .
Switching from one package size to another is also quick and easy. According to Robert Smith, on-site engineering supervisor at SIG Combibloc, switching from one carton size to another takes only eight or nine minutes, and the speed of product switching depends on the product itself. He said: "If you switch from fruit juice to chocolate,
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