K Cup Filling Machine

More Details

After ten years of experience working with customers in this industry, we realized that we could divide our machines into three types and offer the most suitable model according to each customer's specific requirements.

 

Entrance level models: Linear One-Lane and Rotary Filling Machine
Our one-lane filling machines can produce over 50 pods per minute. It can make up to 60 pods per minute if it's a rotary type. These machines have the added advantage that they occupy minimal space. This machine is ideal for a start-up company and entry-level production.

Medium output model: Linear Two-Lane Filling Machine
This model has one more lane than the entrance level model. It can produce up to 90-100 k-cups per minute. Expak engineers have upgraded an extra unique heat-sealing feature unavailable in competitors' machines.

Large output model: Linear Six-Lane Filling Machine
Each lane can make up to 50 pods per minute. Ideal for high-level or low-level production with high capacity to increase output without buying different machines.

Primary Workstation of K Cup filler sealer:

Nitrogen system
The essential part for well-tasty coffee is the Nitrogen injection system; we put it from the cup loaded, filling station, and lid station until sealed. We made this as long and completed a nitrogen gas environment to reduce the oxygen oxidation.
Moreover, we also put a nitrogen injection port in the coffee material hopper, so protection gas like Nitrogen or CO2 could quickly enter the hopper to keep the coffee fresh.
Collaborative and scientific design across mechanical components and nitrogen injection result in residual oxygen up to 1% after lots of testing.

Loading Cup
We have a vertical loader that puts empty K cups into a tube. The tube is 2.5 meters long and acts as a storage space for the cups, saving space. There's a detector in the system that checks if there's a K cup on the mold plate. If there's none, it triggers an alarm to alert the operator. The alarm sound indicates that the cup supply is low, prompting the operator to add more cups for uninterrupted production. If there's any issue, the operator can check the interface, and the PC records any problems in real time.
The UV lamp is also equipped to guarantee food safety.
An anti-static device ensures the product's cleanliness and guarantees the subsequent heat-sealing process.

Doser/Filler
Cone-shaped hopper made of SS304 food grade with a feature of quick-dropping coffee. The drill's drive-by Schneider servo motor precisely controls the auger spinning, achieving high output while ensuring stable mechanical action as a volumetric dosing unit. Also, install a compact agitator inside the hopper and make the coffee flow more uniform to guarantee filling accuracy.

Tamper and Cleaner
At the tamper station, we flatten and even out the filled K cup of coffee. Meanwhile, a vacuum cleaner removes any dust around the cup's edge to ensure a proper sealing process.

Place Lid and then Lid Detection
Implement a preliminary cover with a lid and drop a detector to check it.

Double Heat Seal

Outfeed
Outfeed with Check Weigher to pass suitable K cups to the conveyor belt and refuse bad ones into the trash bin under the K cup filler.

We are willing to provide secondary packaging:

K Cup Cartoning Machine
The carton is automatically opened from a blank slate. Then, a hot melt gluing system seals the cartons automatically, ensuring precision and minimizing errors. At the station, a YAHAMA Robot grabs and loads K cups into the box. These cups can be packed in configurations of 12ct, 16ct, 24ct, and more. For example, in a 12ct configuration, the pods are sorted in positive and reversed order, with two layers in total, each layer being 2 by 3

FAQ of K Cup Filling Machines

1. How does the K Cup filling machine work with the different products?

It could accept products such as ground coffee as granules, herbal tea leaves as a leaf, and soluble powders like chocolate.

The type of cup used depends on the product being filled. For coffee, we use an empty K Cup with a fast filter. For herbal tea leaves, a slower paper filter is used. For soluble powders, we simply use an open K Cup without a filter.

Compared with the manual way of sealing every K Cup, the K Cup filling machine is more automatic and produces more.

The operator can adjust every parameter on the touch screen HMI, such as changing weight from 10.5g to 13g, adjusting capacity, changing machine speed, and doing some sealing tests to get a perfect sealing temperature. 

There are a lot of K Cup fillers that depend on different demands and capacities, small size or bigger capacity, different budgets, etc.
Upon the changeover mold, some machines can be compatible with many single-serve capsules, such as K Cup, K shot, and even Nespresso pod.

2. How does the machine load the empty K Cup?

We give two solutions with advanced technology.



#1 Loading in a Vertical way
It has long vertical tubes that can keep more K Cups stacked and be loaded into the conveyor plate individually. The vertical way saves space by height extension.



#2 Loading in a Horizontal way

We've installed detectors in both directions to keep track of the number of K Cups, so you don't need to worry about loading too few. If there's any issue, the alarm system will alert you.

3. How does the machine fill coffee in K Cup?

The system is a special drill designed and driven by a servo motor.
The Brushless servo motor is powerful and accurate to drive the drill, and then the drill spins to output coffee and put the coffee into every K Cup.
The servo controller controls the servo motor, and you can change the different settings on the touch screen, like PLC translates and outputs signals.
This complete system guarantees the filling accuracy within 0.2g.

If you want to learn the details about Filler System, please click here.

4. How much coffee is in a K Cup?

EXPAK provides premium filter-ready K cups filled with 12-13 grams of coffee, ensuring consistent quality regardless of the ground level. Our filters are of high quality and durable, preventing breakage. Typically, most roasters or brands adhere to filling between 0.3 to 0.4 ounces per cup, equivalent to a net weight of 9.5-12 grams. Overfilling could lead to sealing issues, while underfilling below 9.5 grams may affect taste and result in weak coffee.

5. Are K Cups filled with Nitrogen?

Absolutely, Yes, because it is essential.

With our comprehensive nitrogen protection system, we've achieved outstanding results. Through numerous tests, we've ensured that every single-serving cup has less than 2% residual oxygen, guaranteeing freshness and quality.

This high-level nitrogen system keeps the strong aroma of your coffee, making your K Cups more competitive in the market than others.

6. How are K Cups sealed?

Applying two heat seals is unnecessary to ensure the seal's tightness. You make a nice seal by setting ladder temperature in this two-step sealing: the first step is to seal at a lower temperature, and then the second step is a guaranteed seal at a higher temperature. At the same time, if you make the high temperature in one step, the plastic could be melted and cause the uneven edge of the plastic, and cups will look imperfect.

7. Is the K Cup filling machine challenging to install and operate?

It is not difficult to install. You need to do two things:
1) Connect the air system, which includes both compressed air and nitrogen gas. These systems are located near the bottom of the machine and include a filter and a pressure dial for easy adjustment. 2) Connect the electrical wires to the machine using the Circular Connector that has already been installed. Then turn on the machine, and hit the start button. We are also ready to provide online training for your operators, covering valuable methods and techniques.

8. Maintenance of K Cup Production

Maintenance content:
The machine has three types of items that need to be maintained:

• Drive systems like chains and sprockets.
• Cylinders and filters.
• Electric diagram and wires.

Here we give the guide for drive system maintenance:

The main drive parts are located in the lower half of the equipment,
and the main components include:

1. Primary motor output transmission sprocket, chain;
2. Indexer drive sprocket, chain;
3. Tight sprocket;
4. Machine die plate active shaft transmission sprocket, chain, main drive wheel, passive wheel, mold plate chain;

Maintenance cycle: 3-6 months

1. Lubrication: All the components mentioned above must be lubricated with mechanical grease, including applying it to the wheel tooth position. Once lubricated, the machine is ready to run all its functions and undergo a 5-minute empty cycle to ensure smooth operation.
2. Check if the tightening chain is loose, and replace the chain if needed.
3. Check if the teeth are complete to fix with the chain and replace the sprocket wheel if needed (teeth worn out).
4. Origin check, by operation button: The machine operates in single mold plate mode. To advance one brick, press the white button followed immediately by the black button. Then, compare the encoded value displayed in the upper left corner. If it closely matches the fixed value, it confirms the machine's proper positioning. This step helps detect any deviation from the original position.
5. Check if there is foreign matter in the gear rack, such as coffee pieces, gasket screws, metal debris, etc.
6. Check if the hexagonal screw on the rising sprocket is loose.

If you want to get the complete guidebook for your complete machine maintenance, please contact us by email: info@expakchina.com