Servo Controlled Ultrasonic Nesh Sealing Machine GKV 6800
The GKV 6800 is the top model of our series of machines for ultrasonic net packaging and is characterized by the most modern servo drive technology, a patented net belt drive system for net pull down and several other advantages. The GKV 6800 is equipped with two vertically arranged stainless steel netting tubes with an automatic net tube changing system to refill netting tubes without machine downtime. The net is removed using our patented system with two servo-driven net removal belts operating in both directions. This allows the net to be guided back onto the tube in a controlled manner and the pack to be tightened so that, in addition to traditional loose net bags, also tight stick packs (inline) can be produced.
Optionally, the GKV 6800 can be equipped with a label application (label feeder, thermal transfer printer and add-on kit for TTO), which results in versatile labeling options. For example, packs can be produced with conventional wine glass labels or banderoles (label from weld to weld). In addition, a card dispensing system which adds informative cards into the packs.
The GKV 6800 is designed to be user-friendly and has a pull-out shirring unit so that replacement of the main wear components can be carried out independently without a service call, thus reducing downtime (MDT, MMDT) to a minimum.
Due to the wide range of technical features, the GKV 6800 is the most flexible ultrasonic net packaging machine in the world.
- Pure net packaging without wire clip
- Low wear, low maintenance costs
- Packaging sizes up to 2.5 kg
- Bag length up to 800 mm (longer packs are even possible)
- Suitable for netting tubes with a diameter of 50 — 240 mm
- Patented net belt drive system for net pull down
- Intuitive operation and parameterization via 7″ touch screen
- Various labeling options: Wine glass label of different sizes, banderole (weld to weld)
- Loose bags, tightened stick packings, long tubes and chain packings
- Automatic tube changing system for refilling netting without machine downtime
- Use of sustainable & compostable bio netting e.g. made of PLA (DIN EN 13432:2000–12, EC Directive 90/128/CE, BPI) possible
- Durable, long-lasting welded construction with powder coating (stainless steel version optionally available on request)
- Digital ultrasound station with automatic readjustment unit
- Controlled pneumatic net knife
- Easy maintenance due to retractable net gathering unit
- Pure net packaging without wire clip
- Low wear, low maintenance costs
- Packaging sizes up to 2.5 kg
- Bag length up to 800 mm (longer packs are even possible)
- Suitable for netting tubes with a diameter of 50 — 240 mm
- Patented net belt drive system for net pull down
- Intuitive operation and parameterization via 7″ touch screen
- Various labeling options: Wine glass label of different sizes, banderole (weld to weld)
- Lockere Netzbeutel, gestraffte Stangenpackungen und lange Schläuche
- Automatic tube changing system for refilling netting without machine downtime
- Einsatz von nachhaltigem, kompostierbarem Netz z. B. aus PLA möglich
- Durable, long-lasting welded construction with powder coating (stainless steel version optionally available on request)
- Digital ultrasound station with automatic readjustment unit
- Controlled pneumatic net knife
- Easy maintenance due to retractable net gathering unit
Global market leader in the area of net sealing machines
With the implementation of ultrasonic welding technology in a new generation of net packaging machines, we at Gekupack® succeeded as early as 1994 in taking a step towards species-pure packaging that has received much attention from the industry. The ultrasonic net sealing machines not only eliminate the use of metal as sealing material (clip, clip wire) when sealing the PE net bags (other materials such as PLA are also compatible), but also seal the packages completely and reliably without any additional foreign material. The single-species net packaging produced in this way is thus more sustainable than conventional packaging in many respects and also offers significant economic advantages.
- Netting is way more resource-saving than film material.
- The species-pure packings exhibit a significantly higher recyclability than the corresponding bags with wire clips.
- Our machines feature minimal wear and tear, as the number of wearing parts compared to conventional net clipping machines is drastically reduced to only 3 real wear parts in total.
- The wear components (e.g. the net cutting knife) are easy to replace due to a speacial pull out gathering unit without the need of a service call.
Seit der Erfindung der Netzschweißtechnik auf Basis der Ultraschalltechnologie haben wir unsere Maschinen kontinuierlich weiterentwickelt – auch unter enger Einbindung unserer Kunden. Inzwischen sind die Netzschweißmaschinen nicht nur wesentlich effizienter als dies zu Beginn der Fall war, was mitunter auch auf anderen technologischen Erfolgen und eingesetzten Komponenten beruht, sie sind auch kompatibel mit diversen nachhaltigen Netzmaterialien (z. B. kompostierbarem Netz). Here you can learn more about possible packaging types and materials.
This technique is used in packaging chunky goods such as garlic, confectionery, cheese snacks, peanuts, fat balls, lemons, garlic or onions, potatoes, as well as hardware and toys, such as LEGO bricks, footballs, golf balls, etc..
he high performance and reliability of our ultrasonic net sealing machines, combined with the competence and decades of experience in engineering and manufacturing not only the sealing machines themselves, but also all the necessary additional components to complete entire packaging systems, have led to the outstanding reputation of Gekupack® and have made GK Industries the global market leader in this field. Our value proposition is rounded off by an excellent spare parts availability and supply worldwide.
How does ultrasonic net sealing work?
Ultrasonic sealing has become a popular method in the packaging industry for producing reproducible packs from securely and efficiently welded netting. Ultrasonic sealing is a welding process based on the use of ultrasonic waves and, according to DIN 8580, is one of the main group 4 joining techniques. In this process, the molecules or atoms contained in the materials to be sealed are set in vibration by means of high-frequency oscillations in the ultrasonic range (>20 kHz). The resulting friction effect generates heat, which causes the materials to fuse together and creates a strong bond.
An ultrasonic generator initially generates electrical oscillations (electrical energy) in the high-frequency range. Via a hf-cable these initially still electrical vibrations are applied to the converter (also: ultrasonic head), where the electrical energy is converted into mechanical vibrations using the piezoelectric effect. The converter contains special PZT ceramics that change in length when a voltage is applied. Thus, the applied high-frequency AC voltage causes the ceramics to alternately elongate and shorten, which results in oscillations. The amplitude of the mechanical oscillation is then transmitted to an ultrasonic booster, which is screwed to the converter, and gets amplified or reduced. The amplification factor here depends on the mesh to be welded (such as the amount/volume of netting and the material or the specific energy absorption of the netting). The oscillation movement thus obtained is transmitted via the booster to the ultrasonic sonotrode , which then gets pressed against a counterpart anvil with the netting between both parts. Under pressure of up to 0.7 MPa, the mechanical oscillations are thus transmitted to the workpiece (the netting). For reliable welding to function properly, it is essential that the entire oscillating system is in resonance and that the frequency and amplitude are adapted to the packing material to be welded.
Flexibility meets reliability and performance
The products to be packaged are fed to the ultrasonic net sealing machine from above via a vertically running stainless steel netting tube through our where the nettingis loaded on. The net then gets pulled of with our patented net extraction system mit Riemen und Servo-Antrieben wird die stufenlos wählbare Packungslänge vom Netzrohr kontrolliert abgespult. Dabei bietet unser Netzabzugssystem entscheidende Vorteile gegenüber anderen Systemen – so wird das Netz bspw. über die große, ebene Kontaktfläche very gentle and controlled way. The close-fitting, evenly pressing belt surface wears evenly as it progresses, keeping the packing length consistent and reproducible in a controlled manner!
Before the sealing process starts, the net is gathered by an 8‑finger gathering system. If streamlined bar packs / tightend stick typed bags (inline) are to be produced, the net is additionally wound back onto the filling tube by our reversing net take-off system and the pack is pulled towards the shirring unit, whereby also tight stick packs (inline) can be produced.
Subsequently, the ultrasonic process (see Function and theoretical background) is triggered. The welding energy used and the welding temperatures occurring are monitored during the entire process and get adjusted automatically.This is a decisive advantage, especially in the case of changes during the start-up phase of a production shift or in the case of changing, non-constant ambient temperatures.
ptionally, just before sealing, a label is applied by our label transport system — unwound from the label roll, cut and transported to the position of the weld seam where the label is welded in the same seam. In the process, the label can also get printed via a thermal transfer printer (TTO) ausgezeichnet werden – bspw. mit einem Mindesthaltbarkeitsdatum oder einer Chargennummer.
After a short holding time to cure the weld, the finished packing is separated from the net tube end (the start of the next packing) via a independently controlled pneumatic net knife. The shirring unit then opens and releases the finished pack, which is usually transported away via an outfeed conveyor. While the shirring system is still closed and the sealing process is active, the next dosed products are fed to the net packaging machine.
Depending on the program setting, so-called chain packages can be produced, in which several packages are welded together but not separated. The result is a product containing any number of small packs with the same or different products. After a defined number of welding cycles, the chain pack is cut off from the next chain pack.
As soon as the net on the active filling tubes is used up, a automatic tube change is performed. The operator then can fill/load the empty net tube with new net without this resulting in machine downtime.
The GKV 6800 is operated via a user-friendly HMI (touch screen) . All parameters can be edited (for example, the net length) and saved as a program.
The areas of application of the GKV 6800 servo-controlled ultrasonic net sealing machine are enormously wide-ranging due to the unique combination of maximum performance with maximum flexibility. Thus, with the GKV 6800 net packaging machine, not only fruits and vegetablessuch as garlic, onions, shallots, lemons and other citrus fruits, avocados, potatoes or brussels sprouts, but also feveral other food productssuch as solid chocolate products (chocolate balls, chocolate eggs, chocolate coins) and hollow chocolate figures, cheese snacks, liver sausage and other sausage snacks, smoothies (as secondary packaging of spout pouches) and milk capsules or coffee capsules, can be packed into net bags.
Even in non-food-applications our GKV 6800 gets used. Hardware items, toys, golf balls and footballs, for example, are also packaged in this way.
Moreover, the GKV 6800 is used by the leading manufacturers of Wild Bird Feed for the production of chain packs (mostly shelled peanuts and fat balls in alternation), narrow light peanut sticks made of shelled peanuts and long peanut snakes or peanut tubes with unshelled peanuts, as well as layered feeding sticks with several components (often: sunflower seeds, oat flakes and peanuts).
If you would also like to benefit from the many advantages of the GKV 6800 or are unsure which model and machine version are optimal for your application, please feel free to contact us. We are looking forward to receiving your message.
At a time when regulations require a large number of product information and marketing is more important than ever before, product labeling plays a particularly important role. For this reason, it is of course possible to integrate labeling and label printing directly into the packaging process using a thermal transfer printer. For example, packages with a wine glass label and / or a banderole label from seal to seal are optionally possible. Furthermore, an informative card can be inserted into the packaging.
As an extremely customer- and solution-oriented company, we always strive to supply you with the best possible packaging machines and systems. Therefore, we are also always ready to adapt our standard machines specifically to your wishes and needs as well as to your product and the associated requirements. As a result, the listed technical details of the standard models are not necessarily to be understood as fixed sizes, but rather as variable guide values.
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