Pavan presents the new MRD540 high-speed forming machine at Ipack-Ima in Milan. With quick die change capabilities it is suitable for the production of single sheet ravioli, fagottini and cappelletti and both hard and soft fillings. The demonstration configuration for the fair combines a SPW single-sheet kneader-sheeter machine and lobe pump.

This essential system for fresh pasta is a result of the continual development of Pavan heritage sub-brand Toresani, a Milanese company founded in 1904 which specializes in producing equipment for making fresh pasta. Pavan which was acquired by world-leading technology group GEA in November 2017 is the only vendor to offer complete lines – from  silos to  packaging machines – and is the only key player with a structured research and development unit and  pilot plants for testing products together with customers. With this expertise, Pavan is able to put its signature on fresh pasta, convenience and frozen food machines and product lines, multi-level cookers, machinery for thermal and post-packaging treatment, kneader-sheeters and filled pasta forming machines.

High degree of flexibility

RRW540 double sheet ravioli filling and forming machine (Photo Pavan/GEA)
RRW540 double sheet ravioli filling and forming machine (Photo Pavan/GEA)

The new MRD540 as well as the presented RRW540 double sheet ravioli filling and forming machine has been conceived to respond to a market trend that requires products with a diverse variety of fillings to offer consumers increasingly attractive products. With these machines pasta manufacturers can process a wide range of different products, making production extremely flexible and adaptable to market demands. To even further increase flexibility, Pavan developed a system for fast mold exchange, making it is possible to change the mold and set the phasing in five minutes and switch to a different product manufacturing.

High quality filling

Both machines are equipped with a continuous filling distribution unit driven by a three-phase asynchronous motor with speed variation via a frequency converter for better adjustment of the filling portions. A system of eccentric cams, connecting rods, side guides and bearings facilitates the pusher motion. A system with compensating pistons driven by a cam which is connected mechanically to the main drive by a timing belt, makes it possible to achieve constant filling pressure, thus improving the dosage accuracy and minimizing filling stress due to pressure. This means there is a very low level of mechanical stress to be maintained, thus preserving the organoleptic characteristics of the filling. Furthermore, a volume compensating piston makes it possible to increase the speed of the machine without affecting the characteristics of the filling, and improving the filling distribution through the forming die.

Precision the key to success

It is essential to set the right thickness of the sheet and to keep it constant during the entire processing phase. The sheet thickness is continuously adjustable by means of a central hand wheel with micrometric action and is kept constant using two pairs of adjustable calibrating rolls made of stainless steel, and by direct transmission powered by four engines controlled by an inverter.

Focus on hygiene

In fresh pasta manufacturing it’s essential to provide fully washable machines, so that they can be completely cleaned and frequently. Both machines can be washed completely using soap and a medium pressure washer. All the various motors and gearboxes are protected from corrosion by a coating made of food-grade epoxy paint, STEEL-IT®. In order to avoid the need for grease which could compromise the hygiene of the final product, Pavan always installs a primary drive motor on its fresh pasta machines which transmits the mechanical movement to the other components via belts and gears, meaning no chains (which would need to be lubricated) are required.

No stress for the dough

When the MRD540 is combined with the SPW single-sheet kneader-sheeter machine, the dough treatment is performed without mechanical or thermal stress. At the machine outlet, the pasta sheet has the same temperature as the dough has at the inlet. The sheet comes out velvet-like, uniform, compact and with excellent color. The total capacity of this system ranges from 100 to 1.200 kg/h.

The lobe pump

The MRD540 is combined with a lobe pump for filling dosage. It’s a volumetric pump with helicoidal lobes with speed regulation via a frequency converter. A conical screw feeds the filling into the lobe chamber. This pump can easily dose a diverse range of fillings, including soft fillings, hard fillings and fillings which include whole elements. The machine is composed of an overturning hopper equipped with a detachable reel and lobes and a stainless steel frame on wheels. Its special construction ensures easy disassembly of all parts for cleaning purposes. Stainless steel connectors to supply the filling to the forming machine allow this pump to be installed on both single and double sheet forming machines in place of standard filling. The MRD540 can be coupled with a paddle or screw filling pumps as well.

RRW540 double sheet ravioli filling and forming machine

The filling and forming machine RRW540 is designed to produce double sheets of ravioli with maximum flexibility in filling, from hard meats to liquid or soft cheeses with pieces. With the aim of being able to process even very soft and creamy fillings – food bits included – the RRW540 is equipped with a flexible nozzle dosing system and a jaws driving system which works via a compressed air piston and is equipped with the appropriate lever devices. The system remains fixed to the machine and is inserted automatically when the die moves, without any need of timing or tools. In this configuration, filling is injected by means of a paddle pump; the RRW540 can also be coupled with a lobe pump or screw type dispenser, depending on the kind of filling utilized. A sheet width of 540mm coupled with a maximum speed of 200 strokes per minute allows the RRW540 to reach a maximum capacity of up to 1000 kg/h, ensuring a large production and a quicker return on investment.

Both filling and forming machines can be completely controlled via a touch-screen panel installed on board, equipped with PLC. This regulates the stroke frequency, filling dosing and sheet speed, thus allowing for the very easy management of the machine.

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