The coffee packaging industry has witnessed significant advancements in technology over the past years, particularly, coffee capsules with packaging from and delivered to end-consumers. One such state of art machinery equipment from EXPAK team is the K-Cups variety pack machine—a specialized piece of packaging machine designed to automation packing instead of manual packing K-cups variety pack product. For coffee manufacturers, the innovative machine offers numerous advantages, both operational, efficient and market driven. In this article, we will show what benefits of K-Cups variety pack machine through the machine in production in USA customer site.
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1.What is kcups variety pack machine?
Before the detailed introduction of the variety packer machine, I would like to simply clarify to everyone, including interested coffee manufacturers, what exactly it is.
The Kcups Variety Pack Machine is primarily used for the automated packaging of diverse flavors or blends of single serve coffee capsules, especially in the kcups industry. Is mainly auto collect diverse flavors or blends of kcups into box so the end-customers don’t have to get a carton with all single blend or one flavor kcups but could taste different flavors of coffee from the brand. Meanwhile it could enhance coffee company sales, promotion and stronger connections with customers.
The packaging line is equipped with advanced features such as precision counting, transporting, sorting, case erecting, loading cups, weighing with dump system, and sealing, even some options such as labeling, printing etc. They can efficiently manage different coffee flavors or blends, ensuring that each package is accurately loaded with the desired assortment of pods. This automation reduces manual labor and enhances production efficiency.
2.Background of the customer demand.
As for variety pack product. Variety packs require different flavors, and the quantity of each flavor must be accurate, which requires manual counting and placement before getting this machine, which is very inefficient and sometimes leads to quantity errors. EXPAK provides high-speed packaging solutions, with automatic counting and collection units (which can be changed to different quantities for different products), and is equipped with more automated and stable horizontal carton erector and carton sealers. This set of machines is suitable for different boxes and can solve all variety pack products such as 36ct, 48ct, 80ct, 100ct, 120ct.
3.Each unit of variety pack system
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01. Horizontal case erector:
There is a huge magazine that can hold up to 60 cases. Cam control transporting system to get one flat case to be ready to erect and form, then seal the bottom with glue or tape depending on customer demand. Then output to the roller conveyor with material level sensor, The feature and difference of this horizontal type is better as below:
All movement is through drive gear wheel and cams as mechanical not cylinder, which means more stable and reliable, and no need to adjust or recalibrate again. (this is same concept as our premium filling machine, movements are mechanical hooked inside bottom by drive shaft, and get less pneumatic system involved)
The only thing you need to recalibrate is the case size when different case sizes which different variety packs need to be produced.
While regular vertical ones, mainly are pneumatic system such as cylinder to drive, so reliability is big difference, case/cartons need all each system to work together at same pace, which by cylinder system and drive belts, it always need to adjust after some time of production run(because they run off pace to each other after certain time) and technician need to adjust them to put them together back to same pace to be able to work together.
This makes a big difference in start-up, and long term run of maintenance.
The direction is different, on horizontal system, all cartons are flat lying on the platform, so gravity does not make any difficulty to the carton when they are open, same time actually helps the folding process. While vertical type, grabber/picker only catch one side, and gravity is at vertical direction making some outside factors to pulling down, which cause shape not straight enough, then sides are not line up etc.
And the bigger case with bigger weight, the more of this problem caused by gravity.
02. Lift conveyor system with counting system:
We set up a separate lift conveyor system for each flavor kcup, so it is up to customer needs how many flavors or blends of kcups will be involved in this production. Also equipped with a bigger hopper in the end can hold up to 1000 sealed cups in terms of capacity, manual labor etc.
Customized belt will bring only one kcup every time to ensure that each grid just one kcup, secondary insurance is there is a paddle on the lifter top when two kcups stacked in the grid, it will remove who is on the top. After the rotated paddle, counter sensor started working to count and transfer a signal to PLC that how many cups counted already. When the quantity got reached, it will stop immediately and wait the signal to start again for next cycle. Lift is controlled by servo motor can make sure precision. Operator can change any quantities for each flavor online not must stop machine.
Each flavor will be dropped into a small hopper. When the cups quantity gets reached, the door on the bottom will be open, when each quantity is reached, conveyor belt will integrate all cups and put them into box.
03. Check weigher with dump system:
This is third unit placed after cups loaded into case, operator can set different formulas to relevant products, with Germany HBM weighing sensor and SMC detecting technology to ensure precision, it will pass qualified product if the weight is in this range and dump incorrect product to other side platform so the operator could reput those cups to relevant flavor hopper not waste anything. This is a premium check weigher, better quality machine than others in the market, below are the components applied.
- German HBM gravity sensor
- Japanese Oriental Motor
- Denmark Danfoss inverter
- American Gates synchronous belt
- Japanese SMC solenoid valve
- Japanese Omron photoelectric sensor
- Schneider Electric components
- High-performance industrial touch screen
04. Case sealer:
More stable sealer can keep edges are lined up because apply two separately SEW motors and inverter to control, and debug two motors speed try to be same so that two drive belts’ speed are identical, most of sealers sold are just one motor controls two drive belts, the potential risk is two belts are not in a same speed to run which cause box inside is not line up, then sealed box is in a bad vision which cause uncompetitive product.
4.The Pros of Variety Pack Machines for Coffee Manufacturers
For coffee manufacturers, investing in a K-Cups variety pack machine can be a game-changing decision. Below are some of the key advantages:
01. Enhanced Product Diversity:
Variety pack machines enable manufacturers to offer customers a range of coffee flavors or blends in a single package. This appeals to consumers who enjoy trying different options or who prefer having multiple choices available at home or in the office. By providing such diversity, manufacturers can cater to a broader consumer and boost customer satisfaction which get more orders.
02. Increased Production Efficiency:
Traditional methods of finishing variety packs often involve significant manual labor, which can be time-consuming and easy to get qty errors. A K-Cups variety pack machine automates this process, drastically reducing production time and minimizing mistakes. This improves production efficiency and saves much labor cost for manufacturers. for example, one customer who bought this machine for variety pack production, when we finish set up, they told me before getting this machine, one shift with 8 workers only packs up to 3 pallets, but now it boosts up to 10 pallets and just need one operator and 2 workers to complete all the processes. Our machine speeds up to 12 cases per min which is 720 cases per hour.
03. Improved Quality Control:
Automation ensures consistency in case erecting and packaging each cup. This reduces defects or inconsistencies that could compromise product quality. Reliable quality control translates into higher customer trust and brand loyalty.
04. Cost-Effectiveness in the long term:
While the initial investment in a K-Cups variety pack machine may be significant, it pays off over time by reducing labor costs and improving production speed. Additionally, optimized processes result in less material wastage, further contributing to cost savings.
05. Market Competitiveness:
Offering variety packs gives coffee manufacturers an edge in a competitive market. Consumers are increasingly drawn to brands that provide convenience and choice. By using a variety pack machine, manufacturers can meet these demands effectively, enhancing their market position.
06. Boosting Sales and Revenue:
Variety packs often command higher price points than single-flavor packs due to their added value. Additionally, they appeal to gift buyers and those looking for sampler options, opening up new revenue streams for manufacturers.
07. Reducing Inventory Challenges:
By producing variety packs, manufacturers can manage inventory more effectively. Instead of overproducing individual flavors that may not sell as quickly, they can package slower-moving blends alongside popular ones in a single box, ensuring a balanced inventory turnover.
5.Premium after-sales service-local support with installation and training
EXPAK team is able to send engineers with US Visa to customer site for installation and additional training until leave once it keeps working perfectly in production. EXPAK has 2-3 engineers stay turned to the states and each engineer will stay 6 months so each customer who has the need on machine, they just pop us up. We will arrive immediately. Also, no worries about language, EXPAK team can speak English to communicate. We will attend some exhibitions every year such as SCA, NAMA show, Coffee fest, PACK EXPO etc, most of coffee manufacturers can get regular maintenance every year when we get to the states. It is a such important point when the machine is purchased from overseas.
Conclusion：
The K-Cups variety pack machine is an invaluable asset for coffee manufacturers looking to enhance their product offerings, streamline operations, and stay competitive in an ever-changing market. By enabling the efficient production of assorted coffee capsules, it definitely provides a host of benefits—from increased operational efficiency and cost savings to improved customer satisfaction and revenue growth.
As consumer demand for convenience and choice continues to rise, investing in a K-Cups variety pack machine is not just a strategic move but also a necessity for forward-thinking coffee manufacturers. By embracing this technology, brands can position themselves as leaders in innovation while delivering high-quality products that resonate with their consumers.
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Publication Date: 12/19/2024
Category: Product Events
