TrayFlow

Introduction to the Vormek TrayFlow VES-510

Packaging is no longer just about preserving the product. Today, it is part of brand identity, a tool for proving quality, and a sign of compliance with hygiene standards. As production lines become faster, eliminating human intervention and handing over tasks to automatic, precise systems has become an undeniable necessity.

Among all the stations on a packaging line, the placement of containers onto the infeed has always been a potential bottleneck. Many factories still rely on operators for this task—a method that reduces speed, compromises hygiene, adds cost, and generates recurring errors.

The TrayFlow VES-510 is a servo-driven automatic denesting machine—a response to one of the fundamental needs of modern packaging lines. Featuring a servo motor, screw mechanism, cam-based pre-separation system, and intelligent PLC control, it separates containers one by one with high precision, synchronized with line speed, and places them onto the tray sealer infeed.

The VES-510 is not just another denester. It is an intelligent link in the automation chain—one that enables producers to increase productivity, achieve hygiene standards, and reduce operating costs.

What Is a Servo‑Driven Automatic Denester?

A servo-driven automatic denester is industrial equipment designed to separate nested plastic containers and place them one by one onto the packaging line or tray sealer. This process may appear simple, but in practice, it is one of the most critical points in packaging lines. Even a minor error in separation, improper placement, or multiple containers feeding simultaneously can cause line stoppages, increased waste, and reduced packaging quality.

The VES-510 is designed to solve these exact challenges.

Engineering Architecture

The machine consists of several main sections, each playing a key role in its overall performance.

Feed Conveyor

At the machine’s infeed, a conveyor is designed to hold at least eight container stacks simultaneously. This storage capacity allows operators to load a large number of containers at once, allowing the machine to continue operating without interruption.

Whenever the number of containers in the magazine decreases, the conveyor automatically activates and moves a new stack to the loading position. This feature ensures a completely continuous, uninterrupted feeding process.

Pneumatic Holding Arms – Preventing Shock and Damage

A common problem in denesting machines is the sudden dropping of container stacks onto each other. In the VES-510, two holding arms equipped with pneumatic cylinders are positioned on both sides of the machine to prevent this issue.

These arms:

• Control the weight of the container stack
• Prevent sudden drops
• Gently position containers
• Prevent rim damage to containers

Cam Mechanism – A Solution for Stuck Containers

One of the most difficult challenges in automatic denesting is separating containers that have locked together due to their geometry or material properties. Vormek engineers have developed an advanced cam-based mechanism to solve this problem.

Before containers enter the screw section, this system:

• Applies controlled pressure to container rims
• Loosens stuck containers from each other
• Creates the necessary gap for single-container separation
• Prevents multiple containers from entering the screw system simultaneously

This stage plays a crucial role in the machine’s operational stability, ensuring that even tightly nested containers are separated without issue.

The Heart of the Machine – The Screw System

The core of the VES-510 is its screw system. After containers are positioned in the magazine, four screws—one on each side of the container—engage with the container rim. These screws move in perfect synchronization, gently gripping the container rim.

The process:

• The first container is separated from the stack
• The container is guided toward the outlet
• The next container is prepared for separation

This process is performed without impact, without excessive force, and with the highest precision. Unlike traditional systems, there is no sudden force or mechanical impact.

Servo Motor Power – Precision in Every Motion

The technical superiority of the VES-510 lies in its full servo system—delivering both precision and flexibility. The machine is equipped with two independent servo motors:

• Servo Motor 1: Controls the feed conveyor
• Servo Motor 2: Controls the screw system and separation process

Benefits of Servo Motors:

• Precise speed adjustment
• High-accuracy position control
• Smooth, impact-free motion
• Reduced component wear
• Full synchronization with line speed
• Instant speed increase or decrease capability

Operators can precisely adjust the machine to match production capacity.

Intelligent Control System

In modern industrial equipment, control quality often matters more than mechanical power. The VES-510 features an advanced control system including:

• Industrial PLC
• HMI touchscreen
• Parameter adjustment system
• Speed management system
• Intelligent fault diagnosis
• Alarm and error display

All electrical and control components are housed in an independent electrical enclosure. This design improves safety and simplifies maintenance.

Sensors – The Machine’s Smart Eyes

Precise operation is impossible without a network of sensors and microswitches installed at various points on the VES-510. These components:

• Detect container presence
• Control mechanism positions
• Send feedback to the PLC
• Prevent errors
• Protect operators
• Ensure machine safety

The sensor network ensures full monitoring of the machine at all stages of operation.

Quick Tooling Changeover

Many factories today produce a variety of products in different containers. Flexibility is essential. In the VES-510, tooling changeover is simple:

• Install the appropriate tooling
• Adjust infeed rails
• Adjust conveyor guides
• Set stops to match the new container

The machine can accommodate a wide range of round, rectangular, and other shaped containers.

Hygienic Benefits

In food, pharmaceutical, and dairy industries, hygiene is not optional—it is mandatory. By completely eliminating hand contact with container interiors, the VES-510 delivers:

• Reduced microbial load
• Prevention of secondary contamination
• Enhanced product safety
• Support for HACCP compliance
• Easier quality certification

From the moment containers are loaded until they are placed on the tray sealer, there is no human hand contact with the container interior.

Economic Benefits

Investing in automation delivers value when it generates measurable ROI. The VES-510 reduces production costs through:

• Reduced labor – Many lines require 2–4 operators solely for denesting
• Reduced waste – Precise placement reduces line stoppages and defective products
• Increased capacity – Lines can operate at higher speeds
• Reduced hygiene costs – Lower contamination risk and associated costs

ROI typically occurs within 6–12 months.

Suitable Industries

The VES-510 is suitable for a wide range of industries:

Conclusion

The TrayFlow VES-510 represents the convergence of mechanical engineering, industrial automation, and hygiene requirements in modern packaging lines. The intelligent conveyor, pneumatic holding arms, cam pre-separation mechanism, screw system, two independent servo motors, and intelligent PLC control work together to make denesting a fully automatic, fast, and uninterrupted process.

For producers seeking increased capacity, elimination of human error, reduced operating costs, and improved hygiene standards, the VES-510 is not just an accessory—it is a significant step toward smarter, more sustainable packaging lines.

In an industry where every second is capital and every hand contact is a threat to product safety, the VES-510 takes the first step of packaging with such stability that confidence remains with the producer until the very last stage.

Technical FAQ