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Plastic layer pad systems |
At the start of the 1980's, when the market was dominated by paper based packing materials, ER&GE was the first manufacturer to develop a solution to eliminate the problems of dust, cardboard fibres caused by friction and instability of pallets due to absorption of moisture. Through practical examination of these requirements we developed knowledge and experience which has formed the basis for the production, distribution and cleaning of plastic layer pads. Our business continues to be based on the excellent product characteristics of our layer pads.
Key aspects include hygiene, durability, economy, recyclability and flexibility of design. Consult ER&GE, manufacturers of plastic layer pads and separator sheets.
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ER&GE layer padsER&GE's solid plastic layer pads avoid the problems of conventional packing materials. ER&GE layer pads represent an economical, reusable system that permits washing and disinfecting processes suited to the foodstuffs industry, even after a large number of rotations. Manufactured from recyclable polypropylene, durable product characteristics may be achieved, for example the pads are not subject to contaminating wear and tear in the form of splinters.ER&GE plastic layer pads offer a high level of cleanliness, hygienic and microbiological quality. They are manufactured using virgin raw materials conforming to FDA approved standards, are free from odour and taste and fully comply with the strict provisions of German foodstuffs law. |
Washing and disinfectionER&GE designs and builds its own dedicated plastic layer pad washing machines. The whole process is handled by efficient systems, washing up to 1,500 plastic layer pads per hour. The layer pads are sprayed with hot process water containing detergent and disinfectant and brushed twice. They receive a final rinse in fresh water before pasing through hot air dryers which remove any residual moisture and kill any remaining bacteria at high temperatures. The clean, dry layer pads are stacked on pallets mechanically and shrink wrapped with polyethylene film.The entire process operates inline so that contamination through handling is kept to a minimum. The fresh water supply, chemical dosing and process water recycling is computer controlled which ensures a consistently optimum result. The hygiene standard in the the cleaning environment corresponds with that of a well run bottling plant; the floors are sealed with epoxy resin and both the process water and fresh water systems are built from stainless steel. This enables high standards of hygiene to be maintained throughout the cleaning process. Regular washing helps prolong the useful life of the layer pads and assists in maintaining the grip of the pad's surface. Please consult us regarding layer pad washing, slip, surface embossing or slip angle requirements. |
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We recommend that production areas are subject to HACCP procedures and regular microbiological checks by an independent laboratory such asPMS Micro Limited. The cleaning plant itself should be tested, as well as the process and fresh water, the drying air and finally the layer pads before and after washing. PMS Micro's results show that after cleaning, the layer pads are very low in bacteria and that an efficient washing performance is achieved. After cleaning, a 90% contamination reduction rate is achieved.
In addition, random samples should be taken during the cleaning process for monitoring possible contamination of raw water, fresh water, dirty and cleaned layer pads. We recommend using Biotrace, an ATP based measurement system. This test allows real time monitoring of cleaning process effectiveness. A 6 Sigma statistical analysis has been developed in conjunction with one of our customers, that considers the variability of our cleaning effectiveness over a given period.
The technical characteristics of ER&GE layer pads mean that they represent a standardised yet universal packaging system which reduces technical and administrative complexity for customers and filler companies. We administer all logistical and monitoring matters on a centralised basis. Layer pads from ER&GE offer the following advantages:
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ER&GE layer pads allow
depalletisation systems to be exploited to the full. Production down times
and glass breakages caused by wet or deeply indented cardboard trays are
avoided, whilst the durable elastic properties of plastic layer pads improve
the pack stability of palletised containers. The mouths of the containers
are sealed off by the pads, thereby preventing the entry of dirt particles.
Reusability and recyclability are also important factors when it comes to social responsibility. A company's success is not only determined by direct economic viability alone, but increasingly by the ability to embed business activities in a socially responsible concept. The fact that ER&GE products are ecologically sound helps in an ISO 14000 environment. |
| In normal use, ER&GE layer pads will survive more than 100 cycles. Damaged layer pads can be regranulated and extruded to produce other plastic products. ER&GE layer pads were awarded the environmental symbol of the United Nations in 1984 for their high level of environmental sustainability. Particular praise went to the layer pad's long service life and to the fact that the plastic material is fully recyclable. |  |
ER&GE layer pads may be manufactured in either an extrusion or co-extrusion process. We use extruders which guarantee a manufacturing process that protects the material due to modern design and generous dimensions. Optimised flat sheet dies ensure that the material is distributed homogeneously. High precision callendar rollers with extremely precise temperature control ensure exact thickness, even surfaces and optimum flatness. A particularly long cooling section in an air conditioned production environment ensures stress free cooling to produce shrink resistant, non warping layer pads.
During production, it is important to create mechanical layer pad characteristics such as flexural strength, resistance to pressure and deformation, elasticity and impact strength with thermal, electrical and surface characteristics. If a large number of these characteristics can be combined, the result is a packing standard for a broad spectrum of glass containers and cans.
You only need a small number of different layer pad types without limiting quality, whether processing small jars, aluminium drinks cans or heavy bottles. Glass containers or cans will not slip during transport, but may be swept off with ease during depalletisation. The layer pads will retain their shape under all climatic conditions prevailing in the regions for which they have been designed.
Standardisation and rationalisation represent important objectives. However, these must be weighed against product development and the requirements of special applications. For example, due to the highly flammable contents or aerosol cans, static discharge values must be very low.
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