Carle & Montanari, an Imola, Italy-based Sacmi company, and Carle & Montanari USA, Inc., present a new moulding concept, suitable for all customers, from small to large-sized manufacturers, that offers a low initial investment as well as potential for quick modular upgrades. The new "H" Cavemil Crem moulding line for making chocolate products by various applications such as shell moulds, book moulds, biscuits, wafers, inclusions, or one-shot in all mould sizes can be supplied with different layouts, and its configuration can be easily modified to include new products or extra capacity as needed.
The new "H" Cavemil Crem moulding line's flexibility features the following possibilities: new FV vertical coolers with movable moulds and supporting trays; rotary depositors (type MLR3A), and piston depositors (type MEP3A) suitable for spot, ribbon, one-shot and co-depositing dosing; fast-shell module for shell-moulding; depositors for solid inclusions (types DRPM, MIXOUT, DNR, etc.), cookies (CBR) and wafers (SCV); and book moulding units for chocolate eggs and balls.
As stated, not all segments need to be purchased at once, since customers may select the moulding unit that first matches their actual application need. Thus, they are no longer forced to predict the modules that might be needed in the future. This philosophy allows for a low starting investment, with the step-bystep upgrade coming into consideration if, and when, it is needed for new products or increased capacities.
The "H" shaped layout determines how customers may add new, independent moulding "branches" without touching the main moulding line. A new branch with cooling, for example, allows for a huge capacity increase from potentially 15 to 25 moulds per minute. Additional branches of the "H" Cavemil Crem remain totally independent, with each being run as needed for production; other branches can be switched off for cleaning, maintenance and set-up for new products.
Flexibility of the "H" branch-based configuration also offers the widest possible accessibility of any moulding line in the market. Each point of the moulding line is open and accessible on all sides, and processing areas can be easily reached for setting, cleaning and maintenance operations.
One particular benefit to customers is potentially great savings regarding the number of moulds used for each production run, as well as energy savings for better environmental sustainability. According to the firm, it is not necessary to run a full set of moulds. The number of moulds for each article varies according to the moulding branches in production. While production continues on the main branch, others can be switched off to be cleaned, maintained, and set up for other products, conserving energy for the branches that are not actually running.
As future configurations of the moulding line come onto the drawing board, units are added around it on the "H" branch format without the need to move the demoulding section and therefore eliminating any unwanted consequence of the upgrade on the packaging section. Moreover, any addition of a new module in any of the branches does not require the extensions of the corresponding opposite branch as it happens in the standard layout design.
Additionally, the new "H" layout allows for zero impact upgrading of the existing moulding line. The new branches come mechanically pre-assembled, electrically pre-wired and electronically independent with their own electric cabinet. No modification of existing utilities is needed, such as for chocolate piping, water supply, tempering, etc., but only extensions to connect the new modules.
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