The CORE and RACOP Quick Release Changepart System

The main product of Zepf technologies UK is the 'CORE and RACOP' quick changeover system which is predominantly designed for rotary packaging machines.

The essence of the system is a combination of core components fitted to the machine and removable plastic changeparts for different container shapes and sizes.

The core components become a permanent fixture on the machine. These core components are normally the parts that support star wheels, guides, feedscrews, pedestals or any potential quick release part and are generally manufactured in 316 stainless steel to ensure high quality and reliability at reasonable cost.

For each different container that is planned to run on the packaging line, we manufacture a set of RACOP (RApid Change Over Parts), which are then mounted on the core components.

Easy Identification
The RACOP parts can be produced in a range of 14 colours of 1000 grade Ultra High Molecular Weight (UHMW) polyethylene material. This extensive range of colour coding, unique to Zepf Technologies UK, enables easy identification of different sets of parts and it allows production staff to be confident that each changeover is fully complete, as the same colour will appear along the whole packaging line when it has been changed over for a specific container.

The performance characteristics and resistance to liquid absorption of UHMW polyethylene makes it the most suitable material for use in the food industry.

However, we always select the most appropriate materials for a particular application and on occasion will use:pvc, delrin, nylon, acetal, aluminium and others.

Colour	Pantone No	RAL	British Standard
	01 PURPLE	2665C	4005	BS4800 - 22 D 45
	03 BROWN	4705C	8004	darker than BS4800 - 04 C 37
	04 ORANGE	172C	2012	lighter than BS381C - 592
	05 DARK BLUE	289C	5003	BS4800 - 20 C 40
	08 MAROON	202C	4004	BS381C - 542
	09 RED	199C	3020	BS381C - 539
	10 YELLOW	1235C	1028	BS4800 - 08 E 51
	11 DARK GREEN	316C	darker than 5021	BS381C - 103
	12 LIGHT GREEN	3395C	lighter than 6024	BS381C - 280
	13 WHITE
	14 BLACK
	15 ROYAL BLUE	2935C	5005	BS381C - 166
	16 CHARCOAL GREY	431C	darker than 7000	BS4800 - 18 B 25
	17 BRIGHT PINK	812C	no match	no match

Main benefits
This highly successful system enables machine changeovers to be undertaken by the operators more quickly and efficiently - and notably without the use of any tools.

Customers have been amazed at the time saved on product changes - which can often be as much as 500% - and the simultaneous increase in production output.

A business is therefore able to maximise the use of its main assets, namely people and existing machines, resulting in the highest possible productivity figures.

Other benefits
The Zepf UK system has enabled fundamental changes to take place in container handling, as it allows operators to complete container changeovers with little training, without the use of tools, without the need to time machines - and all with lightweight parts, thereby reducing manual handling issues.

By allowing machine operators to carry out their own machine changeovers, the system creates a sense of ownership, increases motivation and promotes teamwork within a business. Investment in this system releases skilled engineers to carry out other maintenance tasks or essential technical work.

Service and customer care

Zepf Technologies UK has retrofitted parts to all types of rotary packaging machines around the world. In the case of a machine that is particularly difficult to changeover, a Zepf UK designer can carry out a professional survey and 'measure up' at a customer's premises to provide the best possible solution.

Using one supplier for all container-handling parts ensures consistency of design and operation, and minimises operator training requirements. Our installation and commissioning engineers will normally carry out all necessary operator training immediately after installation is complete and advise customers on the best sequence of removal and replacement of the changeparts and also on the best methods of handling and storage of parts for a particular operation.

Once the core components have been fitted to a machine, the design details of the machine are stored in our design database. Every single CORE and RACOP component is allocated a unique number that is engraved on its surface. Urgent replacement parts can normally be despatched within 24 hours of contacting Zepf UK.

If a further full set of parts is needed for additional containers of a different size, after the core components have been fitted to a machine, the lead-time for these parts is significantly reduced. We can also supply standard non-quick change design of parts when required.