Easycube - Portioning Machine

Introduction
Is Fenco’s solution allow the producers/factory to:

• To separate the various production phases (production-portioning from the final packaging)
• Packaging made in a later stage (after freezing) like any other IQF products (ideal for co-packers)
• Lower production costs (minimal losses during processing, and ideal weighing/packaging combinations (by using multy head weighers); thanks to this the % of over weight packaging into final bags is dramatically reduced.
• Weighing and packaging system needed are the same as per the IQF products
• Leafs integrity into final protions
• Made easy to change over parts (moulds for different portion size and shape)
• Convenience a practical usage (product consumption by the consumers)

is a portioning unit specifically designed for leafy products, like:

• blanched cooled SPINACH – MOLOKIA – BEET LEAVES – ENDIVE – CICORY – RAPE FLOWERS, etc.

or for mixed products like:

• spinach & mozzarella cheese;
• spinach & milk cream or sour cream or besciamella;
• cabbage & milk cream or sour cream or besciamella;
• etc.;

During designing we paid attention to some other possible applications, different then the leafy products, out of the leaves season.

“EASYCUBE” can find application to dose/portion other products like:

• pre-frozen liquid/dense or semidense products with solid parts in suspension;
• pre-frozen products in pieces per “veg-burghers”;
• pre-cooked rice or pasta with sauces or vegetables;
• minced meet mixed with vegetables;
• etc.;

“EASYCUBE” can be equipped with “personalised portions design” which help to identify “product and producer” into market and specially from the consumers. “Funny shape” (like: animals, or geometrical shapes) moulds are available for a easy and friendly impact to the younger consumer “kids”.

Working concept

Product is feeded directly into the feeding hopper through an elevator, and the product level is constantly keep under control.

Operation take place in the following sequences:

• Pressing /Forming: system is fully controlled “brushless” motor – actuators, and the logic allow to ad just the speed and the power needed to optimised the results in accordance to the capacity type of product–processing paramethers and final shape. This system allow to control the pressure applicable and to determine the quantity of vegetable/natural water (inside the products) remaining in the final portions.
• Forming / Moulding: by filling the “holes” (female) of the mould. Dimensions/size and shape can be different in accordance to the mould design, and is possible to change it in few minutes just with a different mould “change over part”. The “brushless” motor – actuators and the relevant controls allow the correct filling of the “holes”, in accordance to the pre-settled parameters, like:

• Pressing time;
• Pressing power;
• Type of product;
• Portions dimensions;
• Earlier processing parameters (blanching – cooling);
• Capacity:
• Quantity of water desire into final portions:
• Etc.
• Cutting: is possible thanks a self adjustable “knife” pneumatically controlled. The special material of the knife and the air pressure applied to have the ideal cutting of the product fibres in accordance to the fibres hardness and the blanching cycle applied.

• Portions ejection: a mechanical ejector (male) controlled by “brushless” motor – actuator synchronized with the system provide to eject the portions into the collecting belt conveyor. This conveyor allow to have a visual manual inspection of the same portions before entering into the freezer. This few seconds allow to have a proper de-watering time or allow to spray some extra water into portions before entering into freezer.
• Collecting conveyor: ejected portions are collected/conveyed through a specific belt, that basically drives portions into a freezer, but give also the following possibility:

Last inspection before freezer;

Holding time for better product dewatering;

And eventually

• Pre-glazing (inside and/or outside) always before to enter into freezer; (this solution can be adopted in accordance to the type of freezer available, and not for all type/brands)

• Leaves integrity: thanks to the strong, but gentle action of the pressing unit. Pressing has an alternate motion “up and down”.
• Pressure control: a dedicate software control the power applied in accordance to the type of product and processing parameters.
• Cutting system: due to the type of material and the shape does not need periodically or maintenance/sharpness.
• Automatic operation: a continuous presence of an operator is not required.
• PLC with “touch screen”: an operator or the production supervisor can easily access to the menu of the program for an immediate regulation when needed, in case of differences into the product characteristics.

• Product contamination: being a mechanical system there is not any possibility to have any type of contamination caused by driving fluids.
• Acoustic contamination “Noise”: being a mechanical system the unit does not produce any noise or acoustic contamination, compared to the others hydraulic available machine in the market.
• Very easy accessibility: during designing a lot of attention have been taken to design a machine which allow a really “Friendly” access on each points, during the cleaning and sanification at the end of each shift, and in case of maintenance. The feeding hopper is fixed on railways guide and is easy movable. The system does not include and crane or hoist to dismantle heavy parts, due to the specific design and machine realisation.
• Cleaning and sanification: during designing a lot of attention have been taken also to design a machine with a real minimum point (almost without) any point of dirtness accumulation during operation, moreover the unit is provided of nozzles for a quick washing.
• Periodically cleaning-washing cycle: the system includes a periodical washing of the collecting conveyor belt, to minimise the dirtness and bacterial accumulation during process.
• Water content in the final product: due to the combination of the parts selected and the running control system, the final portion results “less stressed” and in contains higher quantity of vegetable water, and as consequently the portions maintain closer properties of salts, calcium and fibers and other natural characteristics of the fresh products.