After you received the wooden box of the rotary coffee capsule filling machine at your factory, unpack it and unwrap the plastic tapes, and then you need to do several preparation works before starting your real production.
These works may take you several hours.
What should we do before powering on the machine is assemble each component to the main machine.
First, arrange a forklift to remove the K cup filling machine from the wooden box and place it in a proper position.
Then, follow the initial installation instructions(usually a video made by the manufacturer) to assemble all the parts to the main machine one by one.
(Such as the output conveyor belt or vibrating empty capsule sorter.)
Then, plug in the power supply (pay attention to whether the plug matches your local jack).
As for the nitrogen generator and air compressor, assemble them, connect them to the main machine and plug in their own power supply.
Run the air compressor and freeze dryer for several minutes and then confirm from the pressure indicator that the compressed air reached the proper pressure(0.6~0.8MPa).
(The nitrogen generator can be left on this time.)
You need to use a suitable air switch according to the rated power of the machine.
Power on K cup filling machine(turn on the power switch and pressure reducing valve on the machine) and confirm lighting inside the machine with no alarms.
Check inside the machine, confirm that every functions are in their positions and there are space between each function and the table.
This check is to ensure the table is not stuck.
Confirm from the pressure reducing valves that the compressed air reached the proper pressure(0.6MPa around).
Confirm the language in the screen is English.
Turn on temperature controller in the screen.
(Confirm on the right side of touch screen, temperature display screen is lighting up.)
There will be totally two sets of heat sealing unit if the machine use roll stock film.
Press the "manual/auto" button in the screen to switch into “manual” mode in which you can freely select the functions to be performed.
Push yellow [JOG] button at the bottom of control panel 10 ~ 20 times slowly and confirm the jogging is smooth.
Change the page into operation functions page in the screen, and confirm that no function was turned on(all function buttons are gray except for the heating).
Push green [RUN] button on the right of yellow [JOG] button, let machine run for 5 ~ 30 minutes without capsules, films or coffee, and then confirm that the table turns smoothly and no any weird noise.
Test all the functions one by one by pressing a function button on the operation functions page(the pressed function button will turn green) and then pushing green [RUN] button to run each function for several seconds.
Confirm each function is running smoothly.
After all the preparations above, we can try to produce some coffee capsules.
At first, prepare about 3kg coffee, put them into a tank, and then insert the suction tube of the vacuum coffee loader into the tank.
Press [ON] button in a small control panel of vacuum coffee loader to start filling coffee into the hopper inside the machine.
(Fill the hopper more than 50% full.)
Set filling parameters in the touch screen as stated in the following article.
Or follow the video guidance below.
Install the roll stock film as shown in the following video if your machine has this function.
Pay attention to the sealing side and unsealing side of your roll film and make sure the sealing side is down.
Load pre-cut lids to the lids holder if your machine is equipped with it instead of roll stock film cutting system.
Turn on the heater in the touch screen, and confirm from the temperature indicator beside that temperature reaches the set value a few minutes later.
There will be more than one temperature indicator if your machine uses roll stock film.
If your machine is equipped with “Inline weight checker” function, then do the following initial setup.
First open the control box in the lower part of the machine, find the weight indicator, and confirm whether the current displayed value is ZERO.
If it is not ZERO, maybe the gravitational acceleration is the reason of this deviation, then do the calibration operation as shown in the following video.
Then set the scale weight value(equal to filling weight), upper and lower limit according to the following video.
After closing the control box we are done with the weight checker initial setup.
If your machine is equipped with “Vibrating empty capsule sorter” which is used for sorting empty capsules prior to they being loaded to the capsule molds, then do the following preparations.
Press [ON] button in a control panel under the "vibrating empty capsule sorter" to turn it on.
(There are two control panels close to each other which are both on the capsule sorter’s base, one is for itself and another is for the horizontal vibrator beside it.)
Put about 100 empty capsules(depending on you) into the sorter, let several empty capsules automatically line up at the exit tunnel(top of the horizontal vibrator).
Put about 100 empty capsules(depending on you) into the capsule holder if your machine is equipped with it instead of the “Vibrating empty capsule sorter”.
Set the machine speed to 45 or 50 cups/min or a lower number (normal speed).
Switch running mode to “Auto”.
Push green [RUN] button, run your rotary K cup filling machine for several capsules or even all the capsules you loaded into the machine.
Pay attention to the powder leakage rate from the filling nozzle during this production process.
To get a pause, push red [STOP] button to stop running immediately.
To finally end this production, press "Drop cup" function off on the operation functions page(function button turns gray), then no more empty capsules will be fed to the table and machine will stop when it finished all the capsules on the table.
Or you can just wait until the machine run out all the empty capsules you loaded into the capsule holder.
Confirm the result of this trial production.
·the sealing quality
·the filling accuracy
·the unqualified products rejection rate(when equipped with inline weight checker)
·the brewing(check them on coffee brewing machine)
Any unexpected result occurs, contact AFPAK Jeffrey in time.
The last thing we need to do is to do a little cleaning and shut down.
If you are not ready for the actual production right away, then do the following things to complete this preparation.
First, clean the hopper and vacuum the coffee loader as shown in the video.
Then, return them to their original position and clean the rotary coffee capsule filling machine inside.
(Including the table, suck powder head, cutter and the heat sealing head(can wait for it to cool down).)
Then, shut down the air supply on pressure reducing valve and power off the rotary coffee capsule filling machine.
At last, shut down the air compressor and then the freeze dryer.
(Shut down the nitrogen generator firstly if it has been turned on.)
More to read:
Many users always encounter a problem when they first get the AFPAK k cup filling and sealing machine to try to produce, that is, the phenomenon of spreading powder is very serious, resulting in unattractive coffee capsules. This article will analyze in detail the causes and solutions of powder spreading
First of all, to understand the reason for spreading powder, we have to be familiar with the operation logic of powder filling.
The coffee or other powder is rotated inside the filling hopper by the screw/auger, and the powder stored on the screw/auger will flow to the inside of the cup, (this set of mechanisms is not suitable for powder with too good flowability). There is usually a stopper at the lower nozzle to prevent the powder from spreading. And the screw/auger is controlled by a high precision servo motor, and the number of turns of servo rotation to control the amount of powder filling.
Usually, the spreading of powder generated by factors such as wrong parameter settings, cup position is not adjusted correctly, and the powder in the flow of static electricity and other reasons. Next, we will check one by one
This is a relatively common situation. Because the hopper needs to be cleaned frequently, it is inevitable that the position deviation will occur during disassembly, so in the case of spreading powder, the position needs to be lined up:.
After the position are right, if there is still a spreading powder situation, there is a need to check whether the parameter settings are reasonable
The filling parameter setting is made up of two parts: the filling time, and the servo parameters. The two sets of parameters work well with each other to achieve perfect filling
mainly consists of three parameters: Filling/ Filling UP/Down/blender
The filling is to control the time from the beginning to the end of the coffee powder filling, generally set between 950-450
Filling UP/Down is to control the time when the cup starts to come up and drops back to its original position. Generally set between 950-450
Stir is the time to stir the coffee powder in the hopper, which can be ignored.
Note that the above angle parameter settings are based on the value on the machine's encoder, which represents the current machine stop position. Can not be set and changed at will
Generally, after the cup reaches the lower spout, the coffee powder starts to fill, then after the filling is finished, the cup returns to its original position.
When you click on the servo parameters on the left side of the screen, you will see the above page
There are six parameters on this page: Fill weight, Fill Ratio, Fill Servo speed, Clearing speed, Servo acceleration, and servo deceleration.
Fill weight and Fill Ratio is to set the filling weight parameters. you can check this video to learn how to set these two parameters:
Fill Servo Speed is to adjust servo motor turning speed, normally for K cups, we set 1500-2500, and for Nespresso, we set 1000-1500.
Servo acceleration is to set the parameters to start the auger turning, which means how fast the auger can reach the fastest turning speed, normally set 50-300
Servo deceleration is to set the parameter to stop the auger from turning, which means how fast the auger can stop turning, normally set 50-300
We found that the darker the coffee is roasted and the richer the oil is, the more likely it is to generate static electricity during the filling process.
After the generation of static electricity, the coffee powder is more likely to stick to the downstream spout, making the coffee powder transfer to the cup and other parts of the cup during contact with the cup.
Therefore, it is best to configure some electrostatic elimination devices to prevent this type of situation from occurring.
Specific methods of eliminating static electricity can be answered by contacting our sales engineers, who have summarized a set of static electricity elimination solutions based on customer feedback, which substantially helps customers solve many problems of spreading powder.
The above is our summary of the causes and solutions to the problem of spreading powder, there may be other situations that lead to the occurrence of such problems, we welcome feedback from our readers, and we sincerely welcome more comments and suggestions
As one of the first technicians in China to research coffee capsule filling and packaging technology, with more than ten years of front-line sales, design, R&D, and production experience, he has helped hundreds of coffee companies to set up their coffee capsule production lines successfully so far. He has been committed to developing higher-end, more advanced coffee capsule filling and packaging machines and constantly collecting feedback from customers, making AFPAK's machines more and more popular.
The structure of the H2 coffee capsule filling sealing machine includes the empty capsules sorter and feeder device, empty capsules conveyor and filling and sealing zone.
With a vibrating plate, the empty capsules sorter and feeder device is used to sort out all disorganized empty cups so they could be put in order one by one on the conveyor. For H2 coffee capsule filling sealing machine, there would be 2 lanes of conveyor. The conveyor will deliver all the sorted empty cups to the filling and sealing zone.
The filling sealing zone consists of aluminum capsules feeding device, the coffee powder filling system, the nitrogen flushing system, the anti static system, the coffee powder tamping and capsule edge cleaning system, the roll film cutting and sealing station, the second sealing station and conveyor.
The capsules are stocked here and delivered to the conveyor. Basically, the function of this device is similar to empty capsules sorter and feeder device, which is delivering the coffee capsules to the capsules conveyor. But the difference is based on the types of coffee capsules, the empty capsules sorter and feeder device are used to sort out those coffee capsules that are not easy to stack by taking advantage of the vibrating device.
This coffee powder filling system has a conical coffee powder silo which could contain the powder of coffee, cocoa, tea leaves or other type of granules. The coffee powder will be filled into the coffee capsuled in the position of the conveyor.
The nitrogen flushing system is used to keep nitrogen flushed during the process of filling and sealing so to ensure the freshness of the coffee powder and extend the shelf life of filled and sealed coffee capsules.
The static electricity might be generated during the process of filling and sealing, which is harmful to coffee capsule quality and their output, and also the machine itself. Static electricity can cause powder deposition during production to block pipelines. The anti static system will lead to form a conductive layer on the surface of the parts of the machine, thereby reducing its surface resistivity and allowing the static charge that has been generated to leak quickly.
This system is to tamp the coffee powder in the coffee capsules, so to extract the air inside. Also there is edge cleaning function to make sure a complete sealing.
The roll film cutting system would cut the film into the shape of the lid which match the size of the mouth of the coffee capsules. And the system would deliver it to the sealing station for sealing the film to the coffee capsules.
The second sealing station is to make sure the sealing is tight enough and complete. The conveyor would output the well filled and sealed coffee capsules.
In general, the empty capsules sorting and feeding device will be shipped separately. Therefore, after receiving this device and H2 coffee capsule filling sealing machine, customer will need to link them together.
The key thing is put the 2 machine at the right position, so the conveyor of the empty capsules (2 lanes) sorting and feeding device aligns with the conveyor of the H2 coffee capsule filling sealing machine, that the empty capsules can be delivered from the sorting and feeding device smoothly.
After the device is put in the right position, the 2 pipes should be connected.
Further, connect the pipe related the vibration plate. Once it is connected and the switch is on, the device is ready to work.
Firstly, find the screw on the side of the hopper. Release the screw a bit. The the cover will be able to be removed.
Take out the down cover. So the whole hopper could move away from the machine.
Put a bin down the nozzle of the hopper to collect the coffee powder residue after cleaning.
The next step is to find the “clean hopper” on the screen and click the “run” button. So the coffee powder residue will be cleaned drop to the bin.
As on the photo there are some connectors. Take off them.
On the upside of the hopper, there are 4 clamps. Release them. So the whole hopper is ready to open that the auger and other parts could be cleaned.
After cleaning, when putting the hopper back, be careful that the nozzle is in the right position, matching the positions on the conveyor mold.
Click “auto” button, so the machine will carry out production automatically.
“Sorted cup catch” refers to the bio-degradable capsules from the sorting and feeding device.
“Drop cups” is related to aluminum capsules feeding device.
“Filling” means the process of filling the coffee powder to the empty coffee capsules.
“Feeding” refers to delivery the coffee powder from the coffee powder tank to the hopper.
“Film cutter heating” is related to the filling and sealing area’s temperature of “film cutter 1 temp.” and “film cutter 2 temp.”.
“Sealing head heating” refers to the second sealing head.
“Heat sealing 1 temp.” and “Heat sealing 2 temp.” refers to the second sealing station’ s temperature.
“Vibrating sorter” is for sorting out the empty capsules in the empty coffee capsules sorting and feeding device.
“Sorter air blowing” refers to the empty coffee capsules sorting and feeding device.
“Host speed” means the running speed of the machine.
“Fill ratio” is the amount of coffee powder to be filled.
“Fill 1 ratio” and “Fill 2 ratio” are used to adjust the accuracy of the coffee powder not filled accurately. Big number means more coffee powder is filled and small number means less coffee powder is filled.
On the “Operation scree” page.
The blue gear shape button is for manual running or automatic running.
For auto model, the machine will run itself and the relative button will be green.
For manual mode, control each function and press the Green button“Run”. So this function will work.
On the “Parameter screen”.
The parameters are set and tested already. There are many pages on the “Parameter screen”. In general, only “Servo parameters” should be adjusted.
Before you adjust the parameter on “Servo parameters”, you better screenshot the original data.
“Cylinder debugging” refers to control of each cylinder.
“Language” is for setting the language.
Below yellow button “Jog” refers to run the machine for one time.
Green button “Run” refers to running the machine.
Red button “Stop” refers to stopping the machine. When the alarm is on, use the “Stop” button to stop the alarm.
“Emergency stop” is to stop the machine in emergent situation.
An video introduction is as below.
The new roll film will be put on the above parts. Press the air gun to make the film flat as on the video.
The film will go through the sealing station and back to the used film collection parts.
This thick cable is 3-meter long which is the electricity cable. Change the plug and connect it to the power.
There is the switch for the machine to run after all are connected.
This is the part to connect the air compressor. The transparent pipe is used to connect the air compressor.After that, change the position of the blue part to get air supply and the meter color will be changed from green to red. The number will be higher on the meter. The air pressure is set to 0.4Mpa in general. Only this 0.4Mpa is met, could the machine work properly. If it is lower than this number, the machine will not work well. And the alarm will be on.
Lift the top part and rotate it so to adjust the air pressure. After the air pressure is adjusted, press the top part down to the original position.
Below the air compressor connection part, there is the nitrogen generator connection part. The red arrow part refers to the input of the nitrogen. To adjust the pressure level of the nitrogen, you just need to make sure it is a little higher than zero. It does not require high pressure for nitrogen flushing.
Firstly, fill the hopper with coffee powder to make sure the hopper is 80% full. So a constant filling would be ensured. Move the hopper aside to adjust the filling weight with a bin below the nozzles to collect coffee powder.
Find a cup and a scale. Put the cup on the scale and reset the scale to zero.
After, go to the screen. Click the “Filling” and “Stir” and make sure they become green on the “Operation screen”. Press the green “Run” button. So the coffee will start to drop from the nozzles.
If filling weight is set as 5.5, adjust the fill 1 or fill 2 ratio to increase the accuracy.
When filling weight is well set and adjusted, put the hopper back to the right position and lock it.
The inline weight checker is connected to the conveyor (the output part), used to weigh the filled and sealed capsules.
As one of the most popular k cups filling sealing machine in the market, RN1S k cup filling sealing machine has gained great preference among customers. It has helped a lot of startups, small business and medium business to grow, achieve their productivity target and reach their sales goals. To better help customers understand this machine, AFPAK provides here guidance in detail on how the replacement of key parts of RN1S k cup filling and sealing machine is carried out.
Please kindly note when you carry out the below steps to take out or replace the key parts of the RN1S k cup filling sealing machine, you need to make sure the power is switched off and the machine has stopped running. Besides, it is better that the machine is well-cleaned with no coffee powder inside before replacing any parts.
Fours screws close to the top of the cup silo are used to hold the cup magazine to ensure that the cup magazine is stable. So the first step is to unscrew all of them and you will be able to unite the cup magazine. While there are two screws used to tighten the bottom of the cup magazine. After taking off the top of the cup magazine, you need to release the two screws so that the bottom of the cup magazine could be removed. it is quite simple that any one in the factory or the workshop could do it.
When you remove the cup magazines, you need to make sure there is no cup inside. Or if there are cups in the cup silo, hold the bottom of the silo to prevent this cups from dropping and falling to the ground everywhere. Always remember to take the cup silo off gently, in case that the edges would cause wound to the operators.
After the cup magazine is removed, the cup separator should be taken out manually. There are few screws adopted to fix the cup separator which are put on position that could be easily unscrewed. When unscrew the cup separator, be careful of not letting the screws and some parts fall to the ground as some parts are small which might easily drop through the hollow parts of the machine. Hold those small parts while screw them. Besides there are blue and black tubes or tracheae connected to the cups separator, be mindful that you do not cause any damage to them as the screws are hidden inside. Further while removing or taking off the blue and black tracheae, you need to pay attention to the direction of the tracheae, so not to make mistake when connect them back to the cup separator again.
When the new cup separator is ready to be fixed to the machine, you need to firstly tighten the four screws on 2 sides. Then you could fix the bottom plastic cover to the cup separator. So you could put the bottom magazine or the new one back. For this step, the key thing is that you need to be very careful of the position of bottom cups magazine and do not let it touch the cup separator. There is space required between them as the cup separator moves back and forward to separate the cups from the cup magazine and deliver them to the positions on the round plate. There are gaps between two cups stacked in the cup silo which will be taken advantage by the cup separator to realize the cup separating. When cup magazine is set at the right position, screw it to tighten it to the machine.
The last step is to put the blue and black tubes to the right place.
It is quite simple. The filling nozzle are with internal thread. That means basically it is a screw and all you need to do is unscrew the old one and screw the new one to the machine.
The vacuum suction head is stored inside the round shape metal cover. To replace it, the first step is to take it out of the RN1S filling sealing machine. Then open it and take the vacuum suction out.
There are two big screws used to fix the round shape metal cover. You can only take the round shape metal box out after you unscrew the two crews. It is suggested to release the screw tightened horizontally firstly. After that unscrew the vertical screw.
There are four screws on top of the round shape metal cover. After remove those four screws, you will be able to take the top cover off. There will be another screw in the middle for round shape cover. By holding the bottom and unscrewing this screw, you will get the old vacuum suction head out.
Replace the old vacuum suction head with the new one. Then screw it to the round shape metal cover and put it back to the machine and fix it. Hence, the whole process is complete.
The lids magazine is a hollow tube shape part made by metal. It is fixed to the metal lids magazine platform by four screws. To replace it with the new one, all you need to do is unscrew the old one and put the new one on the machine by screwing tightly.
To change the sealing head, you need to release the whole part which contains the sealing head first. There are 2 screws applied to fix the part to the RN1S filling and sealing machine. Unscrew them while holding it to prevent the part from dropping. By taking out the part, you will be able to see the screw at the bottom of the part that fix the sealing head. Unscrew this screw and you will get the old sealing head. Replace it and fix it back to the machine. After putting the whole part to the machine, the whole process is complete.
host location refers to the machine’s main motor location, while host location stuck refers to the main motor having a foreign object stuck in his operation.When you encounter a host location stuck, you need to look at:1. whether there are parts stuck in the machine’s running mold plate platform, if there is a foreign object blocking the running of the mold plate, then please remove the foreign object, generally speaking, like sealing film suction cups and head position misalignment, easy to cause the mold plate blockage can not move forward2. Check if the torque sprocket above the main motor is loose?
Please use a wrench or screwdriver to re-lock the sprocket
Finally, when you have done the above, please press the black stop button below the touch screen to clear the alarm before restarting the device.