Rebuilt Rollstock Thermoformer (HFFS) – Vacuum Packaging Equipment
“All used rollstock machines undergo a full and complete rebuild instead of a simple reconditioning process…”
JVR Industries takes its 50-plus years of vacuum packaging expertise and reinvests it into rebuilt rollstock thermoformer machines. Every used machine we offer for sale undergoes an extensive rebuilding and testing process by experienced technicians. All used rollstock packaging machines undergo a full and complete rebuild instead of a simple reconditioning process to ensure the machine is working like it would if it came out of the factory. Learn more about the JVR Certified Rebuilt Rollstock Thermoformer (HFFS) process below.
Overview of the Rebuild Process
Rollstock machines are originally manufactured in Kansas City, MO, USA. Once a used rollstock packaging machine arrives at JVR, the extensive rebuild process begins. Experienced technicians can customize the rebuilt rollstock thermoformer to make it suitable for a customer’s packaging needs. JVR also stocks the majority of rollstock replacement parts to keep units up and running. On average the rebuilding process takes 120 man hours to complete.
Teardown
Our rollstock technicians strip the used machines down and rebuild them from the ground up. This way, the units look and function as close to new as possible for being a used unit. In general, aluminum and stainless steel components are sandblasted and polished for a clean finish. Every wearable item is replaced, this includes gaskets, seals, bearings, hoses, fittings, valves and more.
Forming Station
Forming Head
During inspection, forming heads are taken off and restored. Corrosion may be seen in the forming head depending on the type of water the previous owners ran through the system, leaving calcium and hard water deposits behind. JVR rollstock technicians drill out the factory plugs and replace them with serviceable plugs. These new plugs make for quick serviceability later down the road. Also, the heads are sent out for new teflon coating. JVR rollstock technicians also replace all of the cords and die plugs, which receive new male and female plugs.
Guards
All old guards are replaced with new polycarbonate guards which have a fully boxed frame (an upgrade from the OEM). The four-sided fully boxed frame has high durability and a solid frame construction.
Forming Die Box
During the forming die box rebuild, we replace all lines, hoses, inner seals, rings, and main die lift bearings. The technicians also replace the exhaust valves for the forming bucket. Most, if not all, of the fittings in the forming die box are replaced. This is because, over time, the quick disconnect fittings don’t release properly. Additionally, the main die lift cylinder, which lifts everything up, is pulled out and rebuilt or often replaced. Then, all inside seals get taken out by technicians to ensure there are no leaks in the forming die box. Lastly, our technicians clean and grease all necessary components before shipping.
Loading Station
Chains
The chains are removed from the rollstock machine during the rebuild process. Any springs or bushings that are worn out are also replaced. If determined that the chain has less than 50% life remaining, we will replace.
Drive Motor
The drive motor moves the chains on the rollstock machine. During the rebuild, the motor is removed, cleaned, repainted, and bench tested. Our rollstock technicians also change the gear oil in the motor before placing it back into the unit. If necessary, they also tear down the gearboxes in the motor and replace the seals if there is any indication of leakage. On occasion, the motor may be rusted and in rough shape. In this case, the technicians replace the motor itself to ensure productivity.
Sealing Station
Sealing Head
We will replace the bladders in the sealing head in addition to any wearable parts ranging from springs, seals, and gaskets.
Stainless Steel Guards
Our service technicians clean up the stainless steel guards. However, if these guards are damaged, they are replaced.
Sealing Die Box
To rebuild the sealing die box, our skillful technicians take out and clean the rails. They also replace the bearings and hoses. Lastly, we use a special grinder to give all components a nice, clean, new finish.
Vacuum Valve Assembly
The vacuum valve assembly is the second heart of a rollstock machine. Most of the time, if anything is acting up on the machine it is likely because of this component. We pull out the assembly and do a full inspection to determine what needs to be replaced. If there are any marks, scoring, or imperfections in the cylinder walls of the aluminum assemblies, the service technicians replace them. At a minimum, the assemblies gets new pistons, springs, and seals. Essentially, any moving parts are replaced. Additionally, we replace old hoses with new ones. We use black hoses for pneumatics, while we use clear or clear blue hoses for the water lines.
Cutting and Discharge Station
Guillotine Knife Assembly
We also rebuild the guillotine. At a minimum, this component receives a new knife. But often, new cylinders are replaced on top, in addition to new hoses and new bushings for the piston guide. Our rollstock technicians bench-test the piston of the guillotine knife assembly. Also, they replace the bushings for the lift mechanism. All components are cleaned and freed up to ensure no components are stuck or seized.
Cross-Cut Knives
Many times, our rollstock technicians replace the cylinder assembly for the cross-cut knives to ensure packages are cut at the appropriate length.
Rotary Knives
We also rebuild the knife assembly as needed. Rebuilt rollstock machines receive new knives and new collars. Over time, the steel holders begin to wallow out resulting in a bit of play, which is why our technicians replace the holders with new ones.
Film Transports
During the rebuild process, we inspect and replace bushings on the film transports. There is a specific level of tolerance that we check to make sure this component is operating as it should be. Additionally, the main bearings are replaced so the dancing arm moves freely. Lastly, the technicians replace all springs, even if they look brand new because there’s no way to tell how much life is left on them.
Motor
The motor in the rollstock machine is taken off, cleaned thoroughly, and repainted for a neat finish.
Vacuum for Trim Scrap
During the rebuild process, we remove the vacuum for trim scrap so it can be cleaned and painted. We also replace any connecting vacuum hoses and lines.
Additional Components
Vacuum Pump
The vacuum pump is the heart of the rollstock machine. Therefore, all our rebuilt rollstock machines with either received a rebuilt Busch or a new JVR RVS series vacuum pump If a Busch branded pump is used, we rebuild and repaint the pump. T, Rebuilt Busch vacuum pumps are fully bench-tested for a long period of time to make sure they are performing at high standards, just like a new rollstock packaging machine would. Our technicians also replace hoses, couplings, exhaust filters, and pump fittings.
Electrical Components
When we start working on used rollstock machines, we always check the electrical components to ensure smooth performance. Initially, we look for signs of corrosion and check for loose components or leaks. Old valve assemblies get converted to SMC valves. If SMC valves are already in place, technicians take them out to clean them. Then, we insert a new valve rack assembly, a new air prep assembly, replace the VFD for a newer, more compact version (which drives the chains), and replace any electrical covers that are missing.
Controls
No corners are cut when it comes to the controls. Every machine receives a new Mitsubishi GOT HMI and FX PLC. The pivoting control arm is replaced along with the HMI enclosure, pushbuttons, and DC power supply.
Final Inspection
Following completion of the rebuild process, rebuilt rollstock thermoformer machines are tested for a minimum of five days. During this time, the machine runs a minimum of one thousand feet of film during which time our rollstock technicians make adjustments to the necessary components. This process ensures that packaging your food products or medical products can occur quickly and efficiently.
After the extensive rebuild, machines can run from a range of 8 to 8.5 cycles per minute. With additional upgrades, the machine can run from 8.5 to 9.5 cycles per minute, especially with a larger pump.
We test each rebuilt machine with a calibrated torr gauge to ensure accurate numbers and confirm there are no vacuum leaks. We often run vacuum tests on the seal die to ensure a proven sealing system. The rebuilt rollstock thermoformer does not get shipped out until the experienced technicians are confident that all components are within specifications and the machine is running smoothly.
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