Clipping Machines and Automation
Poly-clip System's clipping machines form the core of its offerings, providing automated solutions for sealing casings in food packaging, particularly for sausages and other processed meats. These machines evolved from early manual tying methods to sophisticated automatic systems that integrate seamlessly with filling processes, enabling high-volume production while ensuring food safety and operational efficiency.[2]
A pivotal development was the 1967 introduction of the FCA 3401, the first automatic filling-clipping machine using reel clips to produce portioned sausages, marking a significant advancement in automation by replacing labor-intensive manual processes with reliable mechanical closure. By 1978, production reached the 1,000th unit of this double-clipper model, underscoring its impact on industrial sausage manufacturing. Subsequent iterations in the FCA series, such as the 1975 FCA-SUPER 3451 with voiding separator, further enhanced precision by automating portion separation and minimizing filling waste.[2]
Modern clipping machines include a diverse range of single- and double-clippers designed for various scales of operation, from tabletop models for small butcher shops to fully automatic systems for large industrial lines. The ICA series exemplifies double-clippers tailored for larger products, capable of handling calibres up to 200 mm in fibrous, collagen, or plastic casings, with speeds reaching up to 60 cycles per minute when integrated with fillers; higher speeds of up to 300 portions per minute are achievable with series like the FCA for smaller calibres. These machines feature a voiding separator that creates a clean, filling-free tail through precise blade action, reducing material waste and ensuring consistent portioning for products like molded hams or heavy sausages. Sausage hanging machines complement these systems by automatically conveying and suspending finished products post-clipping, facilitating continuous workflow in high-speed environments.[11][12]
Automation is central to Poly-clip System's engineering, with machines boasting compact, robust stainless steel or titanium construction for durability and ease of cleaning, adhering to food-safe standards that prevent contamination during hot- or cold-filled operations. Integration with fillers via mechanical coupling allows for semi- or fully automatic production, where bulk product is supplied directly, clipped, separated, and ejected with minimal human intervention, optimizing throughput and reliability. Features like automatic casing brakes ensure firm filling without overstuffing, while quick-change components and central lubrication systems support low-maintenance operation, extending machine life even in demanding 24/7 settings. This focus on hygienic design and user safety, including smooth surfaces and documented quality controls, positions these machines as benchmarks for efficient, waste-minimizing packaging in the food industry. Recent developments include the 2024 introduction of the FCA Green Series, featuring energy-saving technologies that reduce consumption by up to 5%.[11][13]
Consumables and Packaging Solutions
The Poly-clip System offers a range of consumable clips designed for secure and hygienic packaging closures, primarily manufactured from pure aluminum or food-grade alloys to ensure compatibility with various casings such as fibrous, collagen, and plastic types.[14] The R-Clip, a pre-formed reel clip, is engineered for automatic double-clippers and sealing machines, featuring consistent material hardness, dimensional stability, and clip coding for product detection during the clipping process.[14] This clip type supports secure closures for products like sausages, with options in standard colors and traceability via GTIN-labeled spools.[14]
Building on the R-Clip, the R-ID Clip incorporates advanced RFID technology for enhanced automation, where an integrated chip communicates clip details—such as size, number on the spool, and required die—to the machine control, preventing errors and downtime.[14] Its specialized geometry, including a round bottom contour and modified internal profile, enables bacteria-proof seals when used with plastic casings or aluminum-laminated films, applying uniform pressure for tight, visually clean closures suitable for calibres from 25 g chubs to 160 mm.[14] Both R-Clip and R-ID variants are part of the SAFETY-CLIP SYSTEM, emphasizing hygienic production free from oils and grease.[14]
Complementing the clips, SAFE-COAT is a proprietary food-proof safety coating applied to all Poly-clip consumables, ensuring burr-free, corrosion-resistant surfaces that comply with EU regulations and eliminate contaminants for maximum hygiene in food contact applications.[14] This coating, regularly tested by SGS Institut Fresenius, protects product integrity and reduces machine wear, allowing seamless integration with clipping machines for reliable operation.[14]
Poly-clip loops, made from durable plastic materials, secure packaged products like portion sausages or sliced cold cuts by combining with clips to enable hanging on smoke sticks or trolleys, with features like the SAFE-SEAL system for residue-free release and high load-bearing capacity.[15] Loops are available in customizable colors, including detectable variants, and are spooled with protective shrink-wrapping for transport, maintaining traceability through EAN-coded labels.[15] A notable advancement is the 2008 RFID-integrated spool design, patented under EP1987721B1, which embeds a transponder in a dielectric hub to shield it from metallic interference while storing clip data for automated machine verification, optimizing setup for different product calibers.[16]
These consumables adhere to stringent certifications that underscore their suitability for food packaging. The SGS Institut Fresenius quality seal verifies compliance with LFGB/BedGgstV, Regulation (EC) No. 1935/2004, and EU Regulation No. 10/2011, confirming absence of residues, heavy metals, and color fastness through regular audits.[17] ISO 22000:2018 certification governs the integrated management system for clip and loop production, employing risk analysis like FMEA to prevent contamination across the supply chain.[17] Additionally, Halal certification from HaPI ensures all processes avoid prohibited substances, verified annually by independent audits including PCR-DNA analysis.[17]