This ready-meal (prepared meal / bento) production and packaging line, originating from Italy, integrates automatic tray denesting, precision dosing, liquid filling and MAP (Modified Atmosphere Packaging) sealing into one streamlined system. Built on a modular, PLC-controlled platform with a compact footprint (line length approx. 9.8 m), the entire line can be supervised by a single operator, making it ideal for standardized production of premium chilled ready meals.
Process Flow (6 Stations):
Automatic Tray Denesting — a mobile single-head denester separates empty trays and places them precisely onto the conveyor;
Solid Dosing ① — a Z-type elevator feeds a 4-head linear weigher for accurate portioning of solid ingredients such as potato cubes;
Solid Dosing ② — a second linear weigher doses mixed vegetables (radish, beans, etc.);
Manual Main-Course Placement — the protein patty is hand-placed by skilled operators to preserve appearance and product integrity (flexible manual step for non-standardized items);
MAP Sealing — the tray sealer gas-flushes and hermetically seals 3 trays per cycle, replacing air with protective gases (N₂/CO₂) to extend shelf life without preservatives.
Key Highlights:
High automation: 5 of 6 steps are fully automatic; manual work is retained only at quality-critical points;
Precision dosing: dual linear weighers ensure gram-level accuracy for multiple ingredients;
MAP freshness: inhibits microbial growth, typically extending chilled shelf life to 7–14 days;
Modular & mobile: wheel-mounted modules allow flexible layout with efficient use of vertical space (line height approx. 3.3 m);
Food-grade hygiene: 304/316 stainless steel construction, waterproof motors and control cabinets, washdown-ready for high-pressure cleaning, compliant with international food safety standards.
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