Introducing

MERLIN

When You Need The Best!

The Merlin is a fully automatic F/F/S wrapper designed to form and seal flat film around your product without producing any waste or film trim. This design produces the lowest cost per package and can maintain production speeds up to 100 packages or 120 feet of film per minute depending on model and configuration.  The Merlin Sealer comes with a 16” or 24” wide hot knife cross seal and your choice of a static overlap or thermal bottom seal to satisfy any film requirement. Four configurations of sealing modules are offered to best meet your specific packaging needs.

How Do I Choose?

The Merlin Sealer with Rotary seal head is an excellent choice for low profile packages and best suited for hi-speed operations requiring up to 100 ppm or more. It is perfect to use with most shrink films and comes with the static overlap bottom seal to create a retail level package appearance. Choose the 16” cross seal for package widths up to 14” wide and no taller than 1” high. Choose the 24” cross seal for product sizes up to 22” wide and 1” or less in height. This sealer design requires a minimum amount of maintenance due to very few moving parts and is generally chosen for dedicated product size packaging lines.

 

The Orbital Merlin Sealer is a great choice for packages that have a wide range of cutoff lengths, are taller or grouped in similar size and height ranges and where speeds up to 80 packages per minute are needed. This sealer has a minimum of moving parts and is easy to maintain. It is available in a 16” or 24” cross seal size and comes standard with a static overlap or optional thermal bottom seal based on your film preference.

 

The Stationary Merlin Sealer has the capability to package tall and wide products, utilize flat film for the lowest cost per package and run multiple production shifts in operations where speed is not an issue. This machine design, with its stop and start conveyor system, allows product to be fed into the sealer automatically at speeds up to 15 ppm or more depending on product length.

 

The Reciprocating Motion Merlin Sealer can accept tall and wide products at up to 80 ppm depending on product size and length. The variable speed discharge conveyor has the ability to close the gap between products during the sealing process to minimize overall bag length and further reduce the cost per package. This servo driven sealer is a perfect choice to achieve the lowest overall cost per package compared with other packaging methods including automatic L-sealers and side sealers.

Merlin: Rotary

Standard Features:

- 16” Wide Rotary Hot Knife Sealing System

- Digital Temperature Control
- Hand wheel adjustable controls for simple product change over
- Package speeds up to 100 packages per minute
- Vacuum Belt Transfer Conveyor

3-1/2’ Flighted infeed conveyor

- Fixed Height Film Former

- Multi-Perforator Hole Punch
- Heavy Duty Welded Tubular Steel Frame

- Heavy duty locking casters and leveling pads
- No Product/No Cycle Photo-Eye
- No Air required
- 120 Volt, 20 Amp, power requirement 

- Static Bottom Overlap Seal

Optional Features:

- 8’ or 12’ Flighted Infeed Conveyor Module with Paper Guides (Replaces 3-1/2’ Module)

- Product Management Devices
- Adjustable Height Film Former

- Thermal Bottom Seal

- Belted and Low Pressure Accumulation Infeed Modules

- Reverse Flow Operation

- Custom Integration

Download the 2019 Belco Industrial Brochure

Features & Options

Standard Features

3-1/2’ Flighted Infeed Conveyor with Paper Guides


This variable speed flighted infeed conveyor features vertical drop lugs to bring product up to the mouth of the film former and then disappear for smooth product transfer. These lugs are removable to quickly change the flight spacing for longer and shorter products.




Vacuum Belt Transfer Conveyor


The vacuum belt has a series of holes which pulls a vacuum on the film and creates the drive to convey the film and package out of the film former and into the sealing area.




Powered Film Unwind


Flat film is loaded onto the motorized shaft, located into position with hand adjustable core chucks and automatically feeds film upon demand as the package travels through the film former and into the sealing area.




E-Stops


Emergency Stop Switches are located in convenient locations on the conveyor infeed and control panel to shut off the machine operation in an emergency situation.




Heavy Duty Welded Tubular Steel Frame


Merlin sealers are built to last. You can count on years of trouble-free production. All Belco automatic sealers start with the same premise, a heavy wall tubular steel welded frame. Solid…nothing to loosen…nothing to become misaligned and cause unnecessary wear and downtime.




Stainless Steel Product Contact Surfaces


The various infeed choices available for the Merlin sealers are designed with stainless steel product transfer areas to minimize wear and provide clean and easy to maintain product contact surfaces.




Adjustable Deck Height


Merlin sealers are adjustable from 32.5” to 36” off the ground to easily integrate with upstream and downstream conveyor systems.




Safe Zone Sensor Seal Head Jam Detect


This sensor is located on the sealing head mechanism to avoid the initiation of a seal cycle if product has potentially encroached into the seal area. The seal cycle will abort and skip a seal without causing a jam and any production flow downtime. Available exclusively on the Reciprocating Motion Merlin.




Film Speeds to 120 Feet per Minute


The Merlin Rotary, Orbital and Reciprocating Motion Sealers all have maximum film feed rates of 120 fpm. The Merlin Stationary Motion Sealer has a maximum film feed rate of 80 fpm.




Package Speeds


Depending on the Merlin model chosen and your product size and shape, there are maximum speeds each model can attain for a guaranteed production rate not to exceed these published speeds. The Rotary Merlin Sealer is fastest at 100 ppm. The Orbital and Reciprocating Motion Merlin Sealers are next in speed at 80 ppm. The Stationary Motion Merlin Sealer is rated at 15 ppm.




Variable Speed Discharge Belt


Except for the Rotary Motion Merlin Sealer which uses a roller discharge conveyor, all Merlin Sealers use the same variable speed discharge module to remove product out of the sealing chamber after the end seal is made. By properly adjusting the belt speed for the product, the right amount of film slack can be created to create a strong, tension free seal.




Run/Jog Selector Switch


On all Merlin Sealers, you have the ability to jog the motion of the machine in a slow and controlled manner for ease of setup, product change-overs, testing seal quality and other maintenance and production related operations before switching to Run Mode.




Servo Motor Operation


Depending on the Merlin Model chosen and which type of product infeed conveyor is used, servo motors help precisely control speed, product placement and spacing and motion of the sealing mechanism. These motors are controlled by the Beckhoff PC and have feedback capabilities for reporting all machine conditions which affect production reliability and performance.




Rotary and Orbital Hot Knife


Both the Rotary and Orbital Merlin Sealers use the same style single V-shaped steel blade to both seal and cut the film to make a small, strong bead seal.




Mushroom Seal Blades


Precise temperature control allows the film to be sealed without smoke or residue buildup. A small, strong fin seal is produced. *Available on the Stationary and Recipricating Motion Merlin Machines Only.




Fixed Height Film Former


The film former is designed to have an opening approximately 1/2” wider and taller than your product. It inverts the film about its profile and creates a tube of film into which your product enters to continue the sealing process. *All Merlins come with 1 Fixed Height Film Former. Film Formers come matched to your product size. Additional Fixed Height Film Formers can be purchased.




Multi-Perforator Hole Punch


Belco's most popular air evacuation device allows excess air to escape the sealed bag during the shrink process. This device perforates a 3-row series of pinholes across a 1½" wide area of the shrink film as it unwinds from the roll.




Heavy Duty Locking Casters and Leveling Pads


Belco Merlins are mobile. You’ll find them easy to move from one production location to another for maximum production flexibility and productivity. Once in place, the machine leveling pads can be adjusted to match your tunnel conveyor height and the rest of your production line.




No Product/No Cycle Photo Eye


The infeed conveyor belt runs until a product is detected to begin a new seal cycle.




Static Bottom Overlap Seal


A controlled electrostatic discharge is used to temporarily seal the bottom overlap of film together until the package can finish shrinking in the heat tunnel.





Options

Thermal Bottom Seal


A specially designed and precisely heated seal bar produces a permanent bottom overlap seal to the package by applying contact heat to the film tube as it passes through the film former.




Additional Multi-Perforator Wheel


Adding more perforator wheels provides additional air evacuation for larger packages.




Infeed Conveyor 3-1/2’ Long Paper Guides


Replaces the standard adjustable product guides on the infeed conveyor with L-shaped side guides to manage and prevent thin products from sliding under the product guides.




Auto-Infeed Belted Conveyor


Several styles of belted conveyor modules allow for automatic infeed and operator-less transition of products into the Merlin sealer. Ask your Belco sales representative for engineering guidance based on the specific needs of your product and operation.




Dual Film Roll Unwind


Adds a second powered film unwind to the system for less downtime in between film roll change-overs during production.




Product Hold-Down and Squaring Devices


Used with Flighted Infeed Conveyors, these devices manage and square light and fluffy or stacked shapes and products before entering the film former so they can be properly sealed and shrink wrapped.




Static Pinning Device


A controlled electrostatic discharge is applied to squared product ( such as paper leaflets ) to static pin the stack together until it can be sealed and shrink wrapped.




Empty Bag Blow-Off


An air stream is created across the tunnel infeed to prevent empty shrink bags from entering the tunnel chamber. Recommended for all automatic sealer applications.




Factory Acceptance Tests


Customers are welcome to visit the factory to test run their machines before shipment.




Custom Integration


Belco can help integrate your Merlin sealer with other factory equipment such as feeders, labelers and conveyors.




Custom Programming


Belco designs and builds certain Merlin models with a Beckhoff PC control system which is able to integrate and communicate with your auxiliary equipment and fulfill any production reporting needs.




Fixed Height Film Former


The film former is designed to have an opening approximately 1/2” wider and taller than your product. It inverts the film about its profile and creates a tube of film into which your product enters to continue the sealing process.




Adjustable Height Film Former


The film former is designed to have an opening approximately 1/2” wider and taller than your product. It inverts the film about its profile and creates a tube of film into which your product enters to continue the sealing process. This optional design allows the operator to adjust the opening height to accept packages taller or shorter without having to purchase another former.




208-230 Volt, 3-Phase Power


Belco can design machinery to meet customers’ power requirements. All machines are tested at their rated operating specifications before shipping to ensure a successful start-up.




440-480 Volt, 3 Phase Power


Requires a design change in heating elements, transformers, electrical switches and some other components. Special voltage requests are welcome. All machines are tested at their rated operating specifications before shipping to ensure a successful start-up.




Brush Back Devices


Weighted paddles, industrial bristle brushes, straps and other mechanisms can be designed to help square and orient product so it enters the Film Former to be properly wrapped, sealed and shrink packaged.





Popular Optional Configurations

Extended Height Seal Jaw Opening


Allows for taller packages to be run through the sealer. Ask your Belco sales representative for engineering guidance based on the specific needs of your product and operation.




Rotary Hot Knife Sealing System


The simplest Merlin sealing method uses Rotary motion where a hot knife seals the film, rotates open to allow product to flow under the sealing mechanism and then continues rotating back around to complete the end seal for the package. Rated at film feed speeds of 120 fpm or 100 ppm, this Merlin comes as a 16” or 24” wide sealer.




Reverse Flow Operation


The standard machine build has the operator feeding the machine in a right to left manner. Reverse orientation allows for a left to right operation.




8’ Flighted Infeed Conveyor with Paper Guides


This variable speed flighted infeed conveyor features vertical drop lugs to bring product up to the mouth of the film former and then disappear for smooth product transfer. These lugs are removable to quickly change the flight spacing for longer and shorter products.




12’ Flighted Infeed Conveyor with Paper Guides


This variable speed flighted infeed conveyor features vertical drop lugs to bring product up to the mouth of the film former and then disappear for smooth product transfer. These lugs are removable to quickly change the flight spacing for longer and shorter products.




Custom Color


Belco can custom powder coat paint your machine to match your company colors or production floor requirements. Just supply your RAL paint specification along with your request for machine quote.




Stainless Steel Construction


The Belco line-up of equipment is also offered in stainless steel construction for use in Pharmaceutical, Food, Meat, Fish and Poultry processing environments. They comply with FDA and USDA requirements for packaging your product. These are wipe-down rated machines and not designed for washdown cleaning.




Orbital Hot Knife Sealing System


This Merlin sealing method also uses a rotary sealing mechanism but the hot knife always faces down towards the sealing area. The motion of the hot knife rotates down to make a seal, opens up to allow the package to clear the sealing mechanism and then rotates back around to complete the end seal of the package. Rated at film feed speeds of 120 fpm or 80 ppm, this Merlin comes as a 16” or 24” wide sealer.




Stationary Hot Knife Sealing System


Perfect for multiple shift applications where high speed is not an issue. This 24” wide Mushroom Style Hot knife Sealing System uses a start/stop conveyor to bring spaced product into the sealing chamber where a photo-eye detects the product to initiate the sealing cycle. Upon completion of the seal dwell time, the sealing mechanism opens and the product discharge conveyor moves the sealed package away from the sealing area, allowing for the next cycle to begin. Rated at film speeds of 80 fpm or 15 ppm or better.




Reciprocating Motion Hot Knife Sealing System


This Merlin sealing method provides the most packaging flexibility combined with speed and package cost savings. The 24” wide Mushroom Style Hot Knife Sealing System creates fast and strong seals. The sealing head mechanism initiates a seal and then travels with the package at line speed for the appropriate seal dwell time before opening up and retracting to the home position to begin the next sealing cycle. Rated at film feed speeds of 120 fpm or 80 ppm.




Beckhoff Panel PC Windows Based Control System


An integrated PC and color Operator Interface is mounted on a pendant arm for easy operator use for entering and retrieving recipes for up to 99 packages. The operator friendly Windows program shows all parameter settings as well as alarm conditions, machine state conditions and production rates and package count. All servo motor functions can be controlled through this system.




Dual Side Belt Drive Infeed


A system of two side belt drive modules which bring product into the Merlin in back to back orientation. A properly spaced gap for sealing purposes is created between the two modules before product is transferred into the film forming head by the second module. This feature is standard on the Reciprocating Motion Merlin Sealer.




Product Management Devices


Several types of devices are available as options to help properly guide and control your package as it is prepared for wrapping and sealing and shrinking at production rated speeds.

They include Brush Back Devices, Static Pinning Devices and Product Hold-Down and Squaring Devices.





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