The range development is in conjunction with the procurement of new presses to help D2 accommodate the additional smoothwall foil container and standard wrinkle wall foil container business that has been gained and developed over the last year. With additional diversity in metal supply we look forward to the factory expansion programme commencing in September 2010 as D2 consolidate their position as the number 1 supplier of smoothwall foil containers.

Whilst continuing to explore global markets for new developments, D2 can provide our customer with the assurance of a 100% UK sourced and produced range of smoothwall foil containers. Additional investment in people, production, stacking, handling and distribution are all scheduled to run concurrently.

“Our position enables us now to re-evaluate our strategic partnerships with our European contacts in  the knowledge that D2 will be better placed to service all UK customers with UK produced products from a larger UK factory. D2 are proud to remain the only privately owned foil container manufacturing and sealing machinery business in the UK. There are huge benefits to be gained by the customer who chooses to work with a company that is able to be both proactive, and react quickly when necessary which is obviously not possible when owned by European manufacturers ”

D2 has completed extensive trials in the development of a new style of packaging which consists of a pre-formed Aluminimum Smoothwall Tray & a heat sealed, high clarity APET dome lid.

The technology has been already been seen in the market place however other systems have failed due to the packaging and machinery not being compatible. We overcame this problem quickly as D2 incorporates both Packaging and machinery divisions.

With our D2 Dome System the product sits above the rim of the tray for a full 3D presentation and maximum on the shelf impact.

We are now inviting customers to view our system in action and demonstrate the technical abilities including the option for MAP (modified atmosphere packing) here at our machinery division head office based in Harpenden.

This total solution is only available from D2, so for further details please call 01582 622111.  

The pusher bar conveyor system simplifies production lines by removing the need for complex tray collators. Therefore reducing initial costs and also minimising the need for ongoing maintenance without compromising any output capabilities.

 Available as a standalone machine or as part of a complete line with the option to integrate tray denesters, depositors, volumetric fillers and other online equipment all within the PLC control.

 Our tooling is strong, durable and is designed with efficiency of performance in mind with the MAP versions able to achieve consistent oxygen residuals of less than 1% if required.

 With various formats available, the D2 900 can be specified with a single head arrangement through to eight head tools that can deliver outputs of up to 100 packs per minute dependent on the tray size.

Tray Sealer D2 900

For Further information please call the Machinery Sales Office – 01582 622111

From our machinery base in Harpenden, we have a large showroom set up to demonstrate our latest machinery and also hold our rental fleet of Tray Sealing Machinery.

Our demonstration and rental stock of Tray Sealing Machinery is continuously changing as we have an option to purchase our rental machinery at any point during the hire period. We call this the “Pay As You Go Scheme” and supply a set rebate structure when a machine is initially hired out. This frees up cash flow for our customers and allows them to try before they buy.

Currently we have the following Tray Sealing Machinery available to purchase from our ex demonstration and ex rental fleet;

Ex Rental, MY2003, Mondini CV/VG-S Draw Tray Sealing Machine, with a die area of 320 x 500 we have a Cryovac slice pack tool available suitable for tray size 1825-00, and a D2 D249 Aluminium Smooth Wall Impression Tool.

Mondini CV-VGS Draw Tray Sealing Machine

Ex Demonstration Unit, MY 2006 Mondini E-390 Evoluzione high speed fully automatic in-line, with 3 HS dies, (Pack Machine ideal for ready meals lines), this machine comes complete with tool trolleys and all auxiliary equipment, further full spec on request, This machine is an incredibly high specification and would be perfect for a High Speed packing line.

Mondini E390 Pack Tray Sealing Machine

Ex Rental, MY 2007 Ulma Scorpius 600, Single Lane High Speed Tray Sealer, MAP ready and available with a Red Pump Vacuum System for high oxygen applications. The Ulma Scorpius 600 is a single lane high speed arm designed tray sealer and comes complete with tooling to suit a D276 D2 Aluminium Smooth Wall Foil Trays, and also has a dome tool set used for an ASDA  meat line. This machine would suit a high speed MAP meat application, but could be used in many other single lane operations too.

Ulma Scorpius 600 Tray Sealing Machine

We also have a stock of Conveyors, Depositors, and Tecna Saima Pasta Production Equipment in stock.

Full Specifications and prices are available, please don’t hesitate to contact us for further information.

The reliability and economical running costs of the D2 700 Rotary Tray Sealing Machine, which has been proven by their existing machine’s performance, was key in the decision to buy another one.

The initial D2 700 that they purchased was required to seal, heat sealable film onto Aluminium smoothwall foil trays, which are all supplied as part of a turnkey package by D2 . The strong and consistent seal quality achieved and the impressive durability of the machine convinced them to choose D2 again when a new project for sealing plastic trays came to fruition.

The fact we were able to meet the short delivery time required to meet their product launch date was a further important factor.

The D2 700 is a compact and portable machine which is flexible in terms of changeover and simplicity and is suitable for any tray sealing application whether it  is in ready meals, meats, salads or fruit, to name a few. 

For more information on this and all of our range of tray sealing machinery and associated equipment please contact our sales office on 01582 622111 or via our web contact mail.

Utilising D2’s design capabilities, drawings and initial trial samples were produced following which production quantities were made and checked before introducing regular supplies.

  These containers are ideally suited for catering cheesecakes, crumbles and other catering sized desserts.

 Product requirements determined that some sizes are manufactured with a lanced base, and this facility is available on all sizes. Lancing allows improved heat distribution and so permits even cooking of the product base and is often seen as a must for pastry items.

Like all foil containers, these new dessert sizes are unaffected by temperature extremes and are a strong barrier against moisture gain or loss, flavour and odour.

Hygiene levels are high as foils do not support micro-organisms

Available sizes are:-

Contact us for samples and see how top quality containers produced from top quality tools can enhance and protect your products

As standard our tools include;

• Fused elements – for a Lower consumption of energy and long life.

• Cast element design– ultra reliable and accurate, cast elements disperse the heat evenly around the outer edge of the sealing head ensuring optimum economical performance.

• Flat MAP design – ensuring a vacuum is not created on top of the film, which causes the film to ripple and dome.

• Guaranteed  0.5% residual atmosphere - with MAP tooling.

• Optimum gas consumption – using a vacuum and gas cycle the chamber is designed to optimise gas usage.

• Up to 230°C sealing – for special applications.

• Individual sealing head temperature monitoring – for a more accurate heat control making it possible to use films from 20 micron. (Only available on D2-800 & D2 -900)

• Separate profile cutting knifes – ensuring the maximum life length and highest performance each knife is made using 304 grade Stainless Steel.

• Easy change over design – the change over from one tray size to another is simple and doesn’t require any special tooling, just simply disconnect, remove and re fit.

• Dual SMC pneumatic cylinders operating at 8 bar creating an even seal pressure of 402 kg per cylinder.

• Double anodised aluminium construction – for additional durability in harsh environments.

• Simple wash down – the lower chamber is fitted with a drain tap to allow any excess moisture to drain away.

• Silver core electrical cables - for higher conductivity, durability and long life.

• Seal trays up to 120mm - deep without any modifications

Does your tooling match up?

Please contact us for further information regarding the D2 range of tray sealing machinery and tools.

D2 800 Tray Sealer

 For further information please don’t hesitate to contact the machinery sales team.

This type of tray lidding is commonly used in the airlines and catering industries as well as large scale food service sector for hospitals and prison meals, pub grub and supermarket canteens.

Simple to use and virtually maintenance free the only energy used is manually provided.

For further information please contact our sales team.

We quickly identified the two main areas which required automation, and recommended installing a new D2 Smoothseal 800, fully automatic tray sealer, in-conjunction with a D2 PGS 2100, pre glued fully automatic pre glued Sleever.

The Smoothseal 800 fully automatic in line machine overcame the first issue, which was the time taken to load and unload the D276-75 Aluminium trays from an existing D2 Smoothseal 700, semi automatic tray sealer. Although a semi automatic tray sealer has many benefits such as its very compact design, and mobility, when it comes to speed, the in- line machines are more efficient because of the simple fact a semi automatic machine will only work as fast as the operator, whereas going in line only requires the loading of the trays in to the pusher bar conveyor.

The client’s second problem was the time taken and the amount of labour required to manually sleeve the finished trays, which D2 solved by installing our own D2 PGS2100 fully automatic, pre-glued Sleever. However due to the clients current sleeve not being suitable for an automatic machine, we were required to work with the sleeve producer and the Supermarket to obtain modifications which wouldn’t alter the appearance of the Sleeve or it’s rigidity. After trials with several pre production versions in our workshop, the final prototype was approved and produced, in time for the installation of the line.

Our customer is delighted to confirm that we have achieved the goal of doubling the production throughput, however with the line only working at 60% there is plenty of spare capacity in the packaging equipment for further improvements and savings to be achieved.

If you have a project you wish to discuss please don’t hesitate to contact us to arrange an appointment.

New D2 900 Dome Sealer

The D2 Smoothdome consists of an uncoated aluminium smoothwall tray with a peelable heatsealed high clarity APET dome shaped lid.

It is available in a range of sizes and styles and with pack heights up to 120mm, Smoothdome is the ideal medium for a wide range of convenience food products, including fresh ready-to-roast meat joints, chickens and turkey crowns.

New D2 Dome Lid Technology

The D2 900 tray sealer is a very simple and versatile in-line fully automatic traysealing machine. It is suitable for heat sealing both dome and standard packs in aluminium, board and plastic, with the option of MAP for extended shelf life as well as skin packing. The D2 900 offers the option of hand or automatic tray and lid placing, fast size changeover, touch screen controls, plus servo drives for controlled acceleration and deceleration of the trays when packing very liquid products.

Our D2 Smoothdome is unique. The product sits above the rim of the aluminium tray, achieving full 3-D presentation for maximum brand and on-shelf impact. The peelable seal makes the packs easy to open as well as preventing spillage and ensuring product integrity when in transit and on shelf. Smoothdome is environmentally friendly and the strong and visually appealing pack means there is no need of any outer packaging.

Please contact us for further information and to arrange a product demonstration

This size of tray is now available from D2 in Smoothwall Aluminium !

The new D2 tray has the reference D293-75 and comes with a top out dimensions of 194 x 153 and 75mm deep, additionally the tray features a trivet style embossed base. 

We have introduced this tray so that our customers can enjoy the benefits of using an Aluminium tray, without the cost of replacing expensive tray sealing machine tools.

Using Aluminium trays provides benefits such as high temperature oven or grill cooking, a 100% renewable, and eco friendly material and not forgetting the possibility to microwave product in the tray too.

For further details please contact our sales team.

We truly understand that to achieve a greater environmental reduction we have to look at all aspects of the supply chain not just the finished product.

D2 first led the market in weight reduction with the design and development of our “butterfly” base, enabling a 14.7% weight reduction on one of the most commonly used trays in the market. However after a comprehensive study on the reduction of tray weights across the range we discovered Not all tray re-designs result in weight saving. This is because the blank size of the metal used to form the tray remains the same even if corners are removed.

Since then D2 have invested heavily in multi cavity tooling on all Smoothwall foil containers meaning that we now achieve up to 10% less scrap metal produced during the tray manufacturing process.
Our focus is now to work closely with our customers and deliver new innovations such as enhanced base embosses, internal handles and close effect ribbing. By adding these design features we can offer greater rigidity and weight reduction without loosing any tray capacity.

For Further information Please see the attached PDF document.

D2 Smoothwall Gauge Reduction

We have also been made aware that many of our trays are being offered to customers as sample trays from their own range. This would lead to the assumption that they are not in a position to supply these trays from their own manufacture. Please take a view on any trays that may be sent to you, particularly those which do not fit with their known “cut corner” shape.

 Should you like any clarification on the above, or like to see in more detail our comprehensive range of trays, please do not hesitate to get in touch with myself, your Sales Manager, or the Sales Support team.

Thank you for support.

Yours sincerely

Vanessa Herron

COMMERCIAL DIRECTOR

Tray Sealer Parts

As well as having a structured preventative support package, we can also tailor particular critical spares packages, that can be kept on the shelf ready waiting for that critical moment when your production may need them . . . .

Tray Sealer Spare Parts

We have a dedicated team that solely look after the spare parts assignments for all of our key customers in the UK.

We currently have a large stock of G. MONDINI original spare parts at LOW prices, we also hold a large parts stock holding for other popular tray sealing machines as well as die sets & consumable components . . . .

G Mondini Tooling Available

Call us today to see if we can help your spares requirements.

We are currently running trials on both units and we hope to be able to fully launch into the UK market by November 09.

We will be releasing  further marketing infomation as soon as the trails are complete and the machines go into main production.

Watch this space for further information

D2 600 Tray Sealer

The D2 600 Tray Sealing machine is our entry level Modified Atmosphere Heat Sealing Machine.

D2 600 Semi Automatic Drawer Heat Sealer Layout

The 600 can be used as a standard Heat Sealing Machine or supplied with the MAP (modified atmosphere packaging) controllers and integral Busch Vacuum Pump.

We also have a range of specialist Busch Vacuum Pumps including Red Pumps for high oxygen applications such as red meats, and high capacity Busch Pumps for Skin Packing.

The 600 is a semi automatic Tray sealing machine which uses a drawer system to transport the containers / trays to the die area. A drawer machine is perfect for applications with a lower output, or where batch heat sealing is required. In a standard operation the 600 Semi automatic heatsealing machine can operate between

Plastic Containers

Heatsealing                                                                        6 – 7 Cycles per minute

MAP ( Modified atmosphere packaging )              3 – 4 Cycles per minute

 Smooth wall foil Containers / Wrinkle Wall Foil Containers (G Rim)

Heatsealing                                                                                        4 – 5 Cycles per minute

MAP ( Modified atmosphere packaging)                               2 – 3 Cycles per minute

The D2 600 Tray Sealing machine has been designed using the latest technology to reduce maintenance and make the machine extremely user friendly.

For further information or to arrange a site visit from one of our representatives please contact us and we’ll endeavour to assist your enquiry.

Please contact us for further information and discuss your requirements.

D2 800 Compact In Line Tray Sealer

 The tooling used by the 800 utilises a cast fused elements offering excellent reliability and impressive energy efficiency. The tool sets are incredibly simple and easy to remove and are designed with maintenance, wash down or tool changes in mind. They have been developed to offer a high standard of finish and are extremely price competitive due to the simplicity of the design.

The D2 800 Tray sealing machine has been designed using the latest technology to reduce maintenance and make the machine extremely user friendly.

PLC with Modified Atmosphere Control

The D2 800 is available with a range of optional extras enabling either complete lines or a standalone machine.

Options include;

• Extended In Feed Conveyors
• Tray Denesters
• Depositors
• 1 / 2 or 3 lane configuration
• Powered out-feed conveyors with single lane channelisers
• Full MAP Controllers
• Busch vacuum pumps
• Gas Analyser s
• Vibratory tables for product settling

Common Tray Materials used in the D2 800 Fully Automatic Tray Sealing Machine;

• Smoothwall Aluminium Foil Containers
• Wrinkle Wall Aluminium Foil Containers
• Polypropylene (PP)
• Crystallised polyester terephthalate (C-PET)
• Amorphous polyester terephthalate (A-PET)
• Polyvinyl chloride (PVC)
• Polystyrene (PS)
• High impact polystyrene (HIPS)
• High density polyethylene (HDPE)
• Ovenable Board

For further information or to arrange a site visit from one of our representatives please contact us.

 Normally a product PH range of between 4.5-6.0 is recommended for use in plain un-coated Smooth wall Foil Container, however we have to also consider the product composition, storage conditions and shelf life period, as the PH level could change and a Epoxy Lacquered Smooth wall Container would then be specified.

Products with a PH range of less than 4.5 have been successfully tested and launched using an internal epoxy coating. The Epoxy Lacquer has eradicated corrosion of the tray which in turn has assisted in the extension of shelf life for highly acidic products.

All aluminium containers provide a total inert barrier to oil, water and gases.

Please don’t hesitate to contact us for further information.

The focus in the UK for many years is the recycling of Aluminium Cans (Coke Cans for example), however D2 are continuously marketing the fact that all our aluminium foil containers are also easy to recycle and there is no reason for them to end up in landfill sites. Recycling of used aluminium saves up to 95% energy and there is no loss of quality during the aluminium recycling process, making our trays completely renewable and sustainable.

D2 have been at the forefront of setting the environmental bench mark for the Aluminium Foil Container Industry; however we will continue to look for new ways to reduce wastage through the life cycle of the products we produce.

Smoothseal 700 Rotary Table Tray Sealer

The D2 Pay As You Go rental system is designed to provide greater flexibility for your business. The PAYG offer also allows you an option to purchase the machine at any time during the rental period.

D2 also hold a stock of impression tooling suitable for the D2 Smoothwall Tray Series, currently we have tooling for D249, D232, D233 & D276 sizes. Other impression tooling can be ordered to suit your application.

Please contact us of a bespoke quotation

Compact and mobile the PGS2100 has been designed to work down stream of any single lane conveyor system and can accept trays in a random pattern. Our sleeving machines have many options enabling them to be tailor made to your bespoke requirements, options include extended in & out feed conveyors and also the option to have an ink jet printer inside for barcodes and dates.

Working at speeds in excess of Forty packs per minute the PGSD2100 is extremely cost effective when compared to manual sleeving.

The changeover from one sleeve to the next is very quick and easy enabling the use of several products to be batch run in one shift.

• Compact Footprint
• Mobile
• Adjustable Hopper For Quick Sleeve Changeover
• Accurate and Reliable Rotary Arm System
• Busch Vacuum System
• User-friendly PLC touch screen operator interface.
• Proven and dependable design
• Simple to use and easy clean design

D2 PGS2100 Automatic Pre Glued Sleever

At the same time we have always recognised that our customers have their own individual preferences regarding both the appearance and rigidity of the trays they use. For this reason our new D271-43 smooth wall trays are offered in varying formats.

 For customers packaging light weight products such as mushrooms for example, who prefer the presentation of a plain, clean design, the D271-43 is supplied without any side ribbing and minimal base embossing.

D2 Smoothwall Tray D271-43 Plain Design

Where heavier products are being packed requiring greater rigidity in the tray we offer the D271-43R  version. This incorporate our unique design of tight vertical ribbing on the side walls and pronounced base embossing. These features greatly enhance the strength of the tray whilst giving the added benefit of a fresh and modern appearance.

D2 Smoothwall Tray D271-43 Ribbed Design

Both versions of the trays are available in 100, 105 and 110 micron thickness.

 The D271-43 and D271-43R are part of a family of trays, all with the same top out of 234 x  138mm,and with varying depths from 30-50mm.

For more information on D2 innovations please call the team today to discuss your requirements.

• Highly Experienced Service Engineers

• Comprehensive Parts Stock Holding

• Two UK Service Centre’s

• Maintenance Packages Available 

• D2 Installers and Training Staff

With installations worldwide, D2 have the knowledge and experiance to deal with every type of foil container closures which include;

• Heat Seal Film
• Modified Atmosphere Packaging
• Crimped Board Lids
• Skin Packaging
• Dome Heat Sealed

Please call us for further information on how we can be of service to your business.

The operation consists of a series of vessels arranged in-line with a low to high risk divide where the product is contained by way of lifting and tilting baskets.

 This machine is ideal for high volume, demanding applications where consistency and reliability are the key.

• Unique Vortex Water Agitation System Eliminates Pasta Clumping

• Supermarket Driven Hygiene Standards

• Advanced basket technology for minimal product retention

• High output of evenly cooked product at less than 5 deg c

• Recipe control for simple product changeover

Vortex Cooking System

Call us for further details.

Please send me your comments and feedback on anything you would like to see in this space.