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 specifically designed and manufactured for different container shapes and sizes.

The core components act as a conversion kit and become a permanent fixture on the machine. These core components are normally the parts that support star wheels, guide-rails, 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 onto 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 size of container. Numbered discs can also be fitted to each changeover part to provide a sequence for removal and assembly.

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 manufacture parts using: pvc, delrin, nylon, acetal, aluminium and others including anti-static materials.

Main Benefits

The Zepf UK system has enabled fundamental changes to take place in container handling as it allows operators to carry out 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.

Customers have been amazed at the time saved on product size changes - and the subsequent increase in production output. By using a Zepf UK system a business is therefore able to maximise the use of its main assets, namely people and existing machines, resulting in improved productivity figures.

Product Protection

Zepf Technologies UK has now also developed quick release, height adjustable product protection covers that can be retrofitted to existing changeparts or conveyors.

This is one method of complying with current food and drink legislation. As with our changeparts, these hygiene covers are manufactured from high quality materials, applying our design expertise.

Service and Customer Care

Zepf Technologies UK has retrofitted parts to many 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, minimising operator training requirements. Our installation and commissioning engineers will normally carry out all necessary operator training immediately after the installation is complete and advise customers on the best sequence of removal and replacement of the changeparts. They can also advise 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. All Zepf UK Core and RACOP components are allocated a unique number that is engraved on its surface. By quoting this number urgent replacement parts can normally be manufactured and 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 OEM-style changeparts if required.

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