Barry-Wehmiller Network
  • View Us on Facebook
  • View Us on LinkedIn
  • WordPress
Aftermarket Services

UltraStar Upgradesupgrades_toppic_773x150pix

Javascript link test page

UltraStar Upgrades

Auto Changeover

Bag Top Registration
The Bag Top Registration system allows the bag hanger to maximize production quality and quantity by adjusting the position of the bags prior to placement in the machine’s bag transfer mechanism.

​Bag Length 
The Thiele Star Series Bag Top Registration System operates as two totally independent systems. This system uses a Cognex camera and back light to read the top of the bag. A servo-driven linear actuator optimizes each bag’s position based on data from each of the tray’s individual vision system, regardless of bag length. Should either bag be out of skew tolerance, the bag will be rejected by the existing bag filling station reject mechanism. The vision system is capable of rejecting bags that are skewed 1/8”. 

​Bag Squaring
The two side guides in the bag tray move into a predetermined width after the bag is introduced into the bag tray and prior to the bag being clamped. This movement squares the bag in the positioner. After the bottom of the bag is clamped and the bag picker has control of the bag top, the side guides return to the open position ready for the introduction of the next bag.

​Picking Mechanism
With bag top registration, the bag trays themselves do not pivot the bags up to the transfer belts. Instead, a bag picking assembly with two vacuum cups per bag swings down, applies vacuum, and swings the bag up to the transfer belts. Without the trays swinging to the down position, the bags are stabilized for transfer to station two. While the bags are being swung into the up position the next bag is introduced into the tray, and ​adjustments for the bag height and bag squaring occur. This means no lost production time.

​Menu Driven
Both the bag length and bag squaring are menu-specific for individual recipes. When selecting the new product on the HMI both dimensions will automatically be loaded into the bag top registration. The operators will no longer need to make these adjustments by hand.

Ultrastar_Auto Changeover_Bag Top Registration

Bag Positioner without Vision System
​Bag Length

Servo-driven linear actuators adjust each bag stop individually to corresponding bag length.

​Bag Squaring
The two side guides in the tray move in after the bag is introduced into the bag tray and prior to the bag being clamped. This movement squares the bag in the positioner. After the bottom of the bag is clamped the side guides return to the open position ready for the introduction of the next bag.

​Picking Mechanism
​The bag tray themselves do not pivot the bags to the transfer belts. Instead, a bag picking assembly with two vacuum cups per bag swings down applies vacuum and swings the bag up to the transfer belts. Without the trays swinging to the down position, the bags are quickly stabilized for transfer to station two. While the bag is being swung into the up position, the next bag is introduced into the tray and the bag squaring occurs. This means no lost production time.

​Menu Driven
Both the bag length and bag squaring are menu-specific for individual recipes. When selecting the new product on the HMI, both dimensions will ​be loaded automatically into the bag top registration. The operators will no longer need to make these adjustments by hand.

Spouts
This upgrade provides the components required for the UltraStar to automatically change over when selecting a new product from the recipe screen. One servomotor per spout is used to open and close the spout, and maximum fill rates will be obtained. The fill rate is no longer dependent upon the operator opening the fill spouts to the correct setting.

Ultrastar_Auto Changeover_Spouts

Bag Clamps

This upgrade provides the components required for the Star Series machine to automatically change over when selecting a new product from the recipe screen. One servomotor is used to control the bag clamps automatically, and all bags will have a tight seal against the spout which aids in dust control.

Ultrastar_Auto Changeover_Bag Clamps

Bag Magazine

This upgrade provides the components required for the UltraStar to automatically change the bag stops on the bag magazine when selecting a new product from the recipe screen. Linear actuator automatically adjusts the bag stops on the bag magazine.

Ultrastar_Auto Changeover_Bag Magazine

Auto Height Adjust for Lower Conveyors
This upgrade adds components required to change from a manual air motor to an automatic adjustment to raise and lower conveyors​. The lower conveyors move to the correct height when a new product is selected on the HMI.

Ultrastar_Auto Changeover_Auto Height Adjust Lower Conveyors

Controls

Allen-Bradley 10-inch PanelView Plus Color Touch Screen
This upgrade replaces the push-button control panel with a touch screen. ​An operator can choose between a systems screen, run screen, product sheet screen and a diagnostic history screen. The touch screen has software in it allowing operator communication with the PLC, which eliminates the need for a laptop computer and software to make changes in the PLC. 


Ultrastar_Controls_AB 10in PanelView Plus Touch Screen

Allen-Bradley ControLogix or CompactLogix PLC
The rapidly changing electronic field may require PLC changes​ due to two factors: obsolete componentry and customer-driven changes and requirements. Thiele has standardized using Allen-Bradley PLCs. By doing so, we supply a quality-built PLC and can offer spare parts and replacement parts at substantial savings.

Ultrastar_Controls_AB ControlLogix CompactLogix PLC Upgrade  

Complete Replacement Main Control Enclosure
​Thiele offers a complete main control enclosure replacement. The new panel will come with either a CompactLogix or ControLogix PLC with a safety PLC. This upgrade also updates your safety door switches to meet category 3 safety requirements. New redundant safety switches will be provided. An engineering visit is required prior to order acceptance.

Ultrastar_Controls_Complete Replacement Main Control Enclosure

PLC Scale Controller
This upgrade combines both your scale and bagger into a single integrated system controlled from a single HMI. Included are hardware, software and documentation to add an Allen-Bradley CompactLogix  PLC. Price includes modification to an existing HMI.

Upper Main Drive and Lower Conveyor Servomotor
This upgrade to the 7130 UltraStar replaces the main drive motor, associated clutch, brakes and the right angle gear boxes on the lower conveyor with Allen-Bradley servomotors. ​Through the existing touchscreen, bag transfer speeds and acceleration/deceleration can be adjusted to maximize bagger speed while maintaining firm control of filled bags. Also, maintenance is simplified by the elimination of the need to adjust brakes or replace facings due to wear. The last station works independently to ensures the bags exit the machine at the correct speed depending upon sealer. This facilitates higher transfer rates, resulting in higher production rates. 

Ultrastar_Controls_Upper Main Drive & Lower Conveyor Servomotor

eWON Industrial Router
​The eWON industrial router combines a modem and an IP router for both serial and Ethernet PLC protocols in a single integrated package. This enables a Thiele ​engineer to remotely observe and make changes to the PLC program from his or her work station.

Ultrastar_Controls_EWON Industrial Router

Vacuum Switch Upgrade at Bag Pick Up
This upgrade eliminates the current prox used to activate vacuum at the bag pickup. 
The vacuum switch gives a more positive reading that a bag is actually picked up and ready to be introduced into the bag positioner. The switch may also be used to obtain maximum vacuum from the vacuum transducer. While vacuum is applied, simply turn the vacuum transducer until peak vacuum is shown on the switch. Then lock the vacuum transducer in place. 

Ultrastar_Controls_Vacuum Switch at Bag Pick Up

Vacuum Switch Upgrade at Bag Opening (Spout)
This upgrade eliminates the prox and ring around the bag opening vacuum cup that used to detect whether or not the bag is open. The switch eliminates the problems with adjusting the prox distance in relationship to the ring correctly. The switch may also be used to obtain maximum vacuum from the vacuum transducer. While vacuum is applied simply turn the vacuum transducer until peak vacuum is shown on the switch. Then lock the vacuum transducer in place.

Vacuum Switch at Spout

Oil-less Vacuum Pumps
The oil-less vacuum pump upgrade provides consistent pounds per square inch of vacuum, which results in consistent moving and opening, fewer ​drops and higher production. Less plant air is used which results in higher plant-wide air pressure and a quieter work environment. Total savings of air range from 3.2 to 9.5 CFM (depending on model). 

Ultrastar_Controls_Oilless Vacuum Pumps

Mechanical Upgrades

High Capacity Bag Magazine
The newly designed bag magazine increases capacity of bags on the bag magazine. It allows the bottom end of the bag stacks to hang downward along the backstop, creating fanning that adds greater stability resulting in larger capacity bag stacks.

The following items are included in the magazine:
-Heavy duty mild steel frame with stainless steel deck with an 18” wide uni-chain belt
-16” of the frame closest to the main frame is angled at 15 degrees; the 16” includes an 8” uni-chain belt; the new uni-chain belt used for indexing eliminates belt tracking problems

Ultrastar_Mechancial_High Capacity Bag Magazine

Dual, No-Crush Infeed Roller
This upgrade consists of parts required to convert a single hard roller to a dual soft roller infeed. This upgrade is designed for resealable poly bags with zipper, press to close, and Velcro closures. Works well with all paper bags.

Ultrastar_Mechancial_Dual No Crush Infeed Roller 


Station 1 (Bag Picker Only)
This upgrade adds the bag picker in station one and new stationary bag trays. The bag picker can be used with the existing air cylinder or a servomotor may be added to raise the bags to the transfer belt. Bag width and length will still be changed manually by the operator.

Ultrastar_Mechancial_Station 1 Bag Picker Only

Upgraded Cross Member Mount - Station 2
This upgrade replaces the current 2​" square tube cross members with 1 1/2" tube cross members. This allows more room to adjust the bag opening vacuum cup. Included are new transducer mounts. 

This upgrade allows the operator to easily adjust the bag opening vacuum cup up and down. A ratcheted handle is provided for quick adjustments. Included with this upgrade are air cylinders, mounts, vacuum cups, vacuum cup mounts and flow controls. Note: When installing this upgrade new mounting holes will have to be drilled.

Ultrastar_Mechancial_CM Mount Station-Bag Opening Adjust

New Bag Air Deflation System
This upgrade aids in removing air from poly bags. It's designed to remove air as far as 10" from the top of the bag. The system uses opposing pads working via air cylinders to move them in and out. The system uses 4 linear actuators to move the pads up and down. When a product is first selected the pads move to a preset height. As the bulk density level in the bag changes the operator can manually move the pads up and down using a button on the bagger's HMI.

Ultrastar_Mechancial_Bag Air Deflation System

Station 2 - New Style Lower Conveyor Timing Belts
This upgrade replaces the current Vee belt design with timing belts. As part of the upgrade, the sheave currently used to match belt speed with the upper conveyor is removed. Included with this upgrade is the new style shaker that has three pads in lieu of one.

Ultrastar_Mechancial_Station 2 New Lower Conveyor Timing Belts

Station 3 - New Style Lower Conveyor Timing Belts
This upgrade replaces the current Vee belt design with timing belts. As part of the upgrade, the sheave currently used to match belt speed with the upper conveyor is removed. In lieu of the sheave a gear is used which eliminates the possibility of the lower conveyor being out of sync with the upper conveyor.

Ultrastar_Mechanical_Station 3 New Style Lower Conveyor Timing Belts

Bar Code Scanner Upgrade
This upgrade allows the operator to switch from one product to another using a bar code scanner. The bar code scanner highlights a new product on the operator's touchscreen. The operator must confirm the product on the touchscreen is correct before changeover will occur.

Spout Up, Lock Out Upon Machine Shutdown
​This upgrade locks the spouts in an up position when power is shut down. This is a mechanical assembly and the spouts must be in the up position when power is turned off.

Ultrastar_Mechancial_Spout Locks

Complete New Linerless Spout Assemblies
This upgrade eliminates the need for spout liners. The linerless spout design reduces product leakage while eliminating the inner liner.  Removal of the inner liner eliminates problems experienced with product flow through the flexible boot. It reduces product loss by reducing bad seals caused by leaking of product in the seal area. It also reduces bag transfer and/or jamming problems in bagging unit and sealer associated with leaking product. The overall packaging efficiency is increased while product loss and maintenance associated with product leakage is minimized.

Ultrastar_Mechancial_Linerless Spout

Complete New Max Flo 14-inch Linerless Spout Assemblies
This upgrade allows for a minimum bag width of 11 ½” while maintaining speeds on larger bags. Included with this option are servomotors for the spouts and bag clamps. The spouts and bag clamps will automatically adjust when a new product is selected from the HMI. The combination of servos on the spouts and bag clamps will ensure maximum bag rate and minimal dusting.

Ultrastar_Mechancial_Max Flo Assemblies

Integral Sealers

Integral Poly Bag Sealer
The integral poly bag sealer is installed in the thirrd station of the Star Series bag hanger. The index from the spout to the sealer is the same distance as station one index to the spout. The temperature, ​and dwell time for the sealer are menu specific. When switching from one product to another, the sealer will automatically adjust for the new bag. The sealer works with the following style bags:

-Standard flat tube poly bags
-Standard gusseted poly bags
-Poly bags with a press to close closure feature
-Poly bags with a zipper to close closure feature
-PBOM bags with an inner poly liner or inner foil poly liner where the inner liner requires sealing. The outer PBOM bag will be closed in either the XJX integral PBOM sealer or the Miller Weldmaster Sealer. 

Ultrastar_IntegralSealers_Poly Bag Sealer

XJX Integral Paper Bag Sealer with Dual 3500 Watt Heaters
​Thiele's new design allows the sealer to be split in half along its entire length. For clean out, the sealer section is actuated open, either upon automatic bag jam detection or by the operator simply pressing the clean-out button. These actions lift the folder blade up and out of the way, while one half of the sealer pivots open for easy access. Other features of this upgrade include:
​Speed Synchronization

Previously a nuisance adjustment between bagger exit speed, sealer speed and sealer conveyor speed, the new integral sealer incorporates a unified drive system. This ​guarantees synchronized speed and eliminates the need for a separate sealing conveyor.
Positive Belt Alignment
​The new design reduces maintenance costs and eliminates another hand-off of the filled bag during the sealing process. By incorporating the sealer into the framework of the bagger, smooth and consistent bag transfer is ensured.
​Critical Part Removal and Replacement
The folder blade and heater nozzle are removable, without the use of tools. Both can be removed and replaced in just seconds.
​Increased Speed
Incorporating recently developed design enhancements into the integral sealer has enabled speeds in excess of 150 ​feet/minute to be achieved, increasing production rates.
​Faster Warm Up and Recovery
The above design enhancements ​facilitate greatly improved heater performance. This results in faster warm-up time and increased production due to the quick recovery following changeover, start-up or fault recovery.
Timing ​Belt Transfer
​The use of timing belts for bag transfer is continued through the integral sealing section. This ensures consistent speed and better bag top containment versus the crowned V-belt transfer systems. Also, the problem of belt rollover, inherent of V-belt sealers, is eliminated.

Ultrastar_IntegralSealers_XJX Integral Paper Bag Sealer

Integral Woven Poly and PBOM Bag Sealer
The ​Integral Woven Poly and PBOM Bag Sealer offers many benefits, including:
​Sealing Standard PBOM Bags and Step Down Poly Woven Poly Bags
Sealing temperature, and bag speed through the machine are set when the product is selected from the menu screen.
​Increased Speed
​Recently developed design enhancements allow the integral sealer to reach speeds up to 150 feet/minute, resulting in increased production rates
​Speed Synchronization
Previously a nuisance adjustment between bagger exit speed, sealer speed and sealer conveyor speed, the new integral sealer incorporates a unified drive system. This drive system guarantees synchronized speed and eliminates the need for a separate sealing conveyor.
​Timing Belt Transfer
The use of timing belts for bag transfer is continued through the integral sealing section. This ensures consistent speed and better bag top containment versus the crowned V-belt transfer systems. Also, the problem of belt rollover, inherent of V-belt sealers, is eliminated.
​Positive Belt Alignment
​The new design reduces maintenance costs, thus eliminating another hand-off of the filled bag during the sealing process. By incorporating the sealer  into the framework of the bagger, smooth and consistent bag transfer is ensured.
Note: Zipper top closure bags will not run through the sealer as designed. Removal of the foldover section is required. Price includes a 2-foot extension to the frame and includes additional guarding. Empty bags must be submitted for approval and testing on the sealer.

IMG_1604

Rebuild Program

The complete list of guidelines used for Thiele upgrades can be found here.

BEFORE
Ultrastar_Rebuild_Before

​AFTER
Ultrastar_Rebuild_After