The Marchesini INTEGRA-420 si a continuous motion line designed to form blisters in PVC/ALU (or different materials on demand) and to insert them into straight or reverse flaps tuck-in cartons.  

Main Features

• Monoblock machine composed of two compact sections.
• Design, manufacturing and ergonomics, in accordance with cGMP norms.
• Working zones on operator side, separated from the mechanics placed on the rear.
• High production speed at reduced noise.
• Separated removable bins for collecting rejected blisters, cartons and leaflets.
• Guided adjustments for an easy and quick size changeover.
• CE marking.

Blister Section    

It executes the following functions: 

• forming of PVC pockets;
• product feeding; 
• sealing, cutting and discharge of blisters on the Robocombi belt.

• Continuous motion managed by servo motors.
• Rear housing of two (2) Jumbo forming reels (max. diameter 600 mm each).
• Front housing (operator side) of one (1) lidding reel (max. diameter 300 mm).
• Two splicing tables (one for the forming and one for the lidding film), with hidden cutter and automatic grip vacuum to lock the film in the correct position during the splicing operations.
• Preheating station (with automatic opening in case of machine stop), and forming station, placed in the rear side of the machine.
• Blisters forming station by means of pre-punches and/or compressed filtered air at 0,3 micron for PVC material.
• Horizontal sealing station, following the forming web motion for pressure uniformity.
• Automatic opening of the upper sealing block to protect the product and forming/lidding materials from overheating.
• Cooling plates of the film after the sealing.
• Servo driven independent group for the cutting, perforation and cold coding of blisters by digits.
• Rotating unit for the pick up of the blisters from the die cutter and positive deposit on the connecting conveyor.
• Size parameters (ratio/stroke/temperatures) saved and automatically managed from the PC.
• Quick replacement without adjustments and use of tools, of the size parts referred to: forming, loading plate and product feeding, sealing, coding, perforation and cutting.

Robocombi Feeding Unit

Robotized blisters feeding system, including:

• continuous motion blisters transport system, placed at the outfeed of the blister section;
• robot with suction cups for the blister pick-up, working on 3 axis to execute different kinds of blister stackings on the bucket belt of the cartoning section;
• software for the automatic synchronization of the transfer, pursuit and stacking, in function of the pre-set blister counting; 
• manual loading magazine to reintegrate missing blisters on the transport belt.

Cartoning Section 

It executes the following functions:

• pick up of carton from the magazine by means of suction cups arm;
• carton opening with direct transfer on the toothed transport belt;
• blister insertion into carton by means of 2 servo driven pushers with independent motion, placed opposite the operator side, following the continuous motion of the bucket belt;   
• tuck-in carton closing and discharge.

• Continuous motion managed by servo motors.
• Cartons transport and closing movements running in oil bath, enclosed in two drive boxes.
• 1200 mm long motorized cartons magazine placed on operator side at 700 mm from the floor.

Safeties and Controls

• Safety guards in methacrylate, integrated in the machine frame.
• Emergency circuits and protections with safety level “PLd Cat.3”.
• Machine stop in emergency mode and release of the air pressure.
• Overload control on the machine motorizations.
• Pre-heating times and forming temperatures managed from display.
• Blister reject and loop control.
• Centering blister control inside the cutting tool.
• Splice detection on films, one side.
• Minimum product load control, forming material, lidding material, cartons and leaflets, with machine stop in phase.
• Overload control on pushers during the product insertion.
• Cross control product-carton-leaflet, in absence of product, the machine does not pick up carton and leaflet.
• Carton reject control.
• Machine stop after three consecutive errors of the same type.

Included 

• One (1) size for blisters in PVC/ALU, excluding product feeding parts.
• One (1) pick up size for Robocombi.
• One (1) tuck-in closure carton size without adjustments.       

Optional Accessories

• Tools to process not standard materials like: ALU/ALU, Polypropylene, PET, PVC + Aclar®, COC.
• Forming station with matrix die and punches for ALU material (cold forming).
• Different types of product feeding systems.
• Splice detection on films, two sides.
• Separation of empty and incomplete blisters.
• Forming reel-loading trolley.
• Prefolded leaflet magazine.
• GUK open sheet folder.
• Hot melt carton closure.
• Ink jet or laser carton marking.
• Product control system by camera.