Product Overview
The Junyao JY-ZB1800 is a versatile high-speed confectionery flow wrapping machine engineered to handle the broadest possible range of candy and sweet products on a single packaging platform. Designed and manufactured at Xingjunyao's 13,000 m² facility in Taizhou, Zhejiang, the JY-ZB1800 combines a 3-servo precision drive system, quick-change forming tube technology, and an integrated auto-reject quality control system to deliver production flexibility that is unmatched in the mid-range confectionery packaging segment. From hard candies to soft-filled chocolates, from single-piece lollipops to multi-pack sweet assortments, this machine adapts to product changeovers in minutes rather than hours.
Confectionery manufacturers typically face a difficult equipment decision: invest in multiple specialized machines for different product types, or compromise with a single machine that delivers acceptable but sub-optimal performance across the range. The JY-ZB1800 eliminates this trade-off. Its key innovation is the quick-change forming tube system — a modular assembly that allows the bag-forming tube, guide rails, and infeed tooling to be reconfigured for a different product category in under 10 minutes by a single operator. The forming tube itself is manufactured from polished 304 stainless steel with graduated size markings and a tool-free quick-release clamp mechanism. For manufacturers running 5, 10, or 20 different confectionery SKUs on a single line, this rapid changeover capability directly translates to higher equipment utilization and lower capital expenditure.
The integrated auto-reject system adds a critical quality assurance layer. Products that trigger optical sensors for missing, undersized, oversized, or misaligned conditions are automatically diverted before packaging, and the corresponding film section is marked or skipped to avoid producing non-conforming packs. Reject statistics are logged and displayed on the HMI, giving production supervisors real-time visibility into line performance and enabling data-driven process improvement. With a packaging speed range of 100 to 800 packs per minute and a bag width capability of 40 to 160 mm, the JY-ZB1800 covers the throughput and size requirements of the vast majority of confectionery packaging applications.
Key Features
1. Quick-Change Forming Tube System
The forming tube is the component through which packaging film is folded around the product — and it is the primary changeover element when switching between product sizes or formats. On conventional machines, forming tube replacement requires tools, alignment fixtures, and 30 to 60 minutes of technician time. The JY-ZB1800's quick-change design uses a spring-loaded clamp collar that locks the forming tube in position with a single lever throw. Alignment is self-centering thanks to precision-machined registration pins on the mounting flange. The operator removes the old tube, inserts the new one, throws the clamp lever, and the machine is ready — typically in under 3 minutes for the tube swap alone, with the remaining changeover time devoted to guide rail adjustment and recipe selection on the HMI. Junyao supplies forming tubes in standard diameter increments from 40 mm to 160 mm, with custom sizes available upon request.
2. Auto-Reject Quality Control System
The auto-reject system integrated into the JY-ZB1800 operates on multiple quality criteria simultaneously. Optical sensors positioned before the forming tube detect product presence, verify dimensional conformance against recipe parameters, and check alignment within the guide rails. Products that fail any check are diverted by a pneumatic gate into a reject bin — the diversion occurs between product cycles without interrupting the film feed or sealing operation. The system also monitors seal temperature, film tension, and servo motor current draw, triggering an alert if any parameter drifts outside its defined window. This proactive monitoring reduces the number of defective packs that reach final inspection by identifying process deviations before they produce visible defects. Reject event data is time-stamped and stored for export to external quality management systems via the optional Ethernet interface.
3. Wide Confectionery Range Capability
The JY-ZB1800 is designed from the ground up as a multi-product confectionery platform. The infeed system accepts products with widely varying shapes — round, square, rectangular, oval, and irregular — without requiring extensive retooling between runs. The heated sealing jaw system operates across a temperature range from ambient to 200°C with ±1°C precision, accommodating the different seal initiation temperatures of films used for hard candy (typically higher-temperature seals for puncture resistance) versus soft candy (often lower-temperature seals to prevent product heat damage). The adjustable film tension control ranges from 5 to 50 newtons, enabling the machine to run thin, flexible films for lightweight products and thicker laminated films for heavier items without reconfiguration.
4. 3-Servo Drive with Multi-Profile Control
The 3-servo system controlling film feed, longitudinal seal, and transverse seal/cut operations supports multiple motion profiles that can be selected and tuned for different product characteristics. For fragile products like filled chocolates or wafer-based sweets, a soft-start/soft-stop profile reduces acceleration forces on the film and product. For rigid products like hard candies, an aggressive trapezoidal profile maximizes throughput. The servo drives maintain synchronization within ±0.3 mm of positional accuracy at all speeds, and the control system automatically compensates for the slight differences in film elasticity between different film materials and suppliers — a common source of registration drift in less sophisticated machines.
5. PLC+HMI with Product Recipe Management
The 7-inch color touch screen HMI serves as the command center for the JY-ZB1800, with a recipe management system capable of storing complete parameter sets for up to 50 different products. Each recipe includes: film feed speed and tension settings, longitudinal and transverse seal temperatures, cut-off length, bag width (forming tube diameter reference), product infeed timing, auto-reject tolerance bands, and selected motion profile. Recipes can be named, organized into product families, and exported to USB storage for backup or transfer to other JY-ZB1800 machines. The interface includes production counters (shift, daily, and lifetime totals), maintenance interval reminders based on operating hours, and a graphical fault diagnostic screen that pinpoints sensor trips and drive errors on a machine schematic diagram.
6. CE-Certified Stainless Steel Construction
The JY-ZB1800 is built on a fully welded 304 stainless steel frame with food-grade surface finishes throughout the product zone. All structural welds are continuous and ground smooth to eliminate crevices where product residue could accumulate. The electrical enclosure carries an IP54 rating as standard (IP65 optional for washdown environments), and all external cabling is routed through sealed conduit. The machine complies with CE safety directives including emergency stop circuits with dual-channel redundancy, interlocked safety guarding on all access points, and electrical isolation that meets IEC 60204-1 requirements for machinery safety. A comprehensive technical file supporting the CE declaration is available for customer review and local regulatory submissions.
Technical Specifications
| Parameter |
Specification |
| Model |
JY-ZB1800 |
| Packaging Speed |
100 – 800 packs per minute |
| Bag Width Range |
40 – 160 mm |
| Bag Length Range |
50 – 350 mm (adjustable) |
| Film Width (Max) |
400 mm |
| Film Tension Range |
5 – 50 N, adjustable |
| Power Supply |
380V / 50Hz, 3-phase (customizable) |
| Power Consumption |
5.0 KW |
| Drive System |
3-servo (film feed, longitudinal seal, transverse seal/cut) with multi-profile control |
| Forming Tube System |
Quick-change, tool-free, self-centering clamp |
| Auto-Reject System |
Multi-criteria optical + temperature + tension monitoring with pneumatic gate |
| Sealing Temperature Range |
Room temperature – 200°C ±1°C |
| Seal Type |
Fin seal (back) + end seal (transverse), pillow pack |
| Film Material Compatibility |
BOPP, CPP, PE, metallized film, cold-seal, laminated composite |
| Machine Weight |
880 KG |
| Machine Dimensions (L×W×H) |
2,550 × 1,320 × 1,650 mm |
| Frame Material |
304 stainless steel, fully welded, IP54 enclosures (IP65 optional) |
| Control System |
PLC + 7-inch color HMI touch screen |
| Product Recipe Storage |
Up to 50 presets, exportable via USB |
| Language Support |
English, Chinese, Spanish, French, Arabic, Russian |
| Certification |
CE |
| Optional Features |
Auto film splicer, nitrogen flush, date coder, hole punch, gusset device, remote access module, additional forming tube sizes, dual-infeed conveyor, product counting/batching system |
Applications
The JY-ZB1800's defining characteristic is its breadth of application. Rather than being optimized for a single product category, it delivers strong performance across the full confectionery spectrum — making it the preferred choice for manufacturers with diverse product portfolios, contract packagers serving multiple clients, and growing companies that expect their product range to expand over time.
Hard Candy (Boiled Sweets, Drops, Lozenges): Hard candies are typically the least demanding product category for flow wrapping, but high-speed production exposes weaknesses in film tracking and seal consistency. The JY-ZB1800's 3-servo system maintains registration accuracy at sustained 800 PPM operation, and the multi-profile drive can be set to the aggressive trapezoidal motion profile that maximizes throughput with rigid products. The auto-reject system catches chipped or broken hard candies that are common byproducts of high-speed candy manufacturing and cooking processes.
Soft Candy and Chews: Soft caramels, fruit chews, toffees, and nougat pieces require balanced temperature control that achieves a strong seal without transferring excessive heat to the product. The JY-ZB1800's independently controlled sealing jaws with ±1°C precision maintain this balance. The adjustable film tension prevents the stretching that occurs when soft products create inconsistent drag on the film during forming tube passage.
Filled and Center-Filled Candies: Liquid-center, cream-filled, and jam-filled candies add complexity because the filling can leak if the product is compressed during packaging. The JY-ZB1800 addresses this with the soft-start motion profile and the auto-reject system's ability to detect external leakage (visible as surface wetness or film discoloration in the optical inspection zone). The machine can also be configured with a slightly oversized bag to reduce lateral pressure on filled products.
Lollipops and Stick-Mounted Products: The quick-change forming tube system is particularly valuable for lollipop manufacturers who package multiple sizes — from mini 8-gram pops to large 30-gram display lollipops. The infeed guide system includes stick-accommodating channels, and the auto-reject system can be configured to detect missing sticks (a common manufacturing defect) that would otherwise reach consumers inside sealed packaging.
Manufacturing and Quality Assurance
The JY-ZB1800 is manufactured at Xingjunyao's facility under documented quality procedures that govern each production stage. Raw material inspection includes chemical composition verification of stainless steel grades, hardness testing of machined components, and electrical safety certification of all purchased sub-assemblies including servo motors, PLC controllers, and HMI panels. During assembly, each forming tube is verified for concentricity and surface finish using laser profilometry, and the quick-change clamp mechanism is cycled 500 times to confirm repeatable alignment accuracy. The completed machine undergoes a 4-hour continuous run-off test at rated speed with actual confectionery products — typically a sequence that includes hard candy, soft candy, and filled candy to demonstrate the quick-change capability.
Quality documentation is a deliverable with every machine. Customers receive a factory acceptance test report detailing the machine's performance during run-off, a calibration certificate for the temperature control and servo positioning systems, an electrical safety test certificate, and the CE declaration of conformity. This documentation package supports customer quality audits and facilitates local regulatory compliance filing in destination markets. Junyao maintains digital copies of all quality records for the service life of each machine, enabling traceability in the event of any field inquiry.
Frequently Asked Questions
Q: How many different products can the JY-ZB1800 realistically run on a single shift?
With the quick-change forming tube system and stored recipe presets, a single experienced operator can complete a full product changeover in 8 to 12 minutes. This means a typical 8-hour shift can accommodate 6 to 10 product changeovers while still achieving reasonable production volumes per SKU. The practical limit is determined more by the time required for upstream process changes (candy cooker settings, cooling tunnel adjustments) and downstream packaging line reconfiguration than by the JY-ZB1800 itself. Many customers report that the machine's rapid changeover capability has allowed them to consolidate from two or three dedicated packaging lines to a single JY-ZB1800 installation.
Q: What happens when the auto-reject system identifies a defective product?
When a product triggers any reject criterion, the pneumatic diverter gate activates within the time gap between that product and the next in the infeed stream — typically a window of 50 to 75 milliseconds at full speed. The rejected product is directed into a locked, removable collection bin. The control system simultaneously compensates the film feed and sealing cycle to account for the missing product, preventing the creation of a short or malformed pack. The event is logged with timestamp, reject reason, and product lane identifier. If the reject rate exceeds a user-defined threshold (e.g., more than 5 rejects in 60 seconds), the HMI displays a warning and can optionally pause the machine for operator investigation — preventing extended production of defective output when an upstream process has degraded.
Q: Can the JY-ZB1800 run cold-seal films for heat-sensitive products?
Yes. The JY-ZB1800 fully supports cold-seal film operation. The heated sealing jaws can be disengaged with the heating elements switched off, and the machine's film path and tension control remain fully functional. Cold-seal films require pressure rather than heat to create the seal, and the JY-ZB1800's jaw pressure is adjustable to accommodate this. The machine's registration system continues to operate normally with cold-seal films, tracking either printed eye marks or running in fixed-length mode for unprinted film. Changing between heat-seal and cold-seal modes takes approximately 5 minutes — primarily to allow jaw cooling before handling.
Q: What is the expected service life of the forming tubes?
The forming tubes are manufactured from 304 stainless steel with a polished surface finish (Ra ≤ 0.4 μm) that resists film abrasion. Under normal operation with standard BOPP or CPP films, forming tubes remain in specification for 5 to 8 years of production use. The primary wear mechanism is gradual polishing of the film contact surface at the tube collar entry point, which eventually reduces the self-lubricating effect of the polished finish and may cause subtle film feeding inconsistencies. Forming tubes are individually serialized and their replacement is tracked through the machine's maintenance log. Junyao maintains forming tube stock for all standard sizes and can manufacture custom sizes with a lead time of approximately 15 working days.
Q: How does Junyao support customers who are new to automated confectionery packaging?
Junyao provides comprehensive onboarding support for first-time automated packaging customers. This includes: pre-sales consultation where application engineers review product samples and recommend the optimal machine configuration including forming tube sizes, film specifications, and optional features; on-site installation supervision and commissioning by a Junyao technician or certified local partner; operator training covering daily operation, product changeover, basic troubleshooting, and cleaning procedures; and remote diagnostic support via the optional Ethernet access module. Junyao also provides film supplier recommendations and can facilitate trial runs with sample films to identify the optimal film grade for each customer's specific products and distribution requirements. A detailed operator manual is provided in the customer's preferred language.
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