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Maker - Product Challenge

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Changemakers

<span style="font-weight: 400">At last, you reached the final stage of processing your product - welcome to the packing world! Packing preserves and protects a product from damage, spoilage, and contamination while it makes its way from the production line to the consumer or further production. Depending on which industry your products belong to, the type of primary packaging equipment can change drastically. You need to pay careful attention to products with </span><span style="font-weight: 400">chemicals or hazardous substances since they can be potentially dangerous to human health. </span>

Packing

Sugar is the fuel that drives photosynthesis in plants. The leafy organisms constantly convert water and carbon dioxide into glucose. But it takes manufacturers specialized sugar processing technology to extract the sweet crystals from them. Today, most sugar products are derived either from sugarcane or sugar beet.

Sugar

If you want to pack into eye-catching 4-side sealed sachets between 40x50 mm and 250x200 mm in size, investing in a reliable sachet machine will be a good investment.


<h2>Fast and flexible solution for your sachet needs</h2>
The Sachet Machine series SA 300 &amp; SA 600 by VikingMašek are continuous motion multi-lane sachet machines. They make eye-catching 4-side seal packets using just one roll of packaging film that can seal your product with high speed and efficiency.

The versatile multi-lane sachet machines can accommodate from 1 to 6 lanes (SA600) or from 1 to 10 lanes (SA600) to form sachet pouches, running as fast as 80 cycles per minute.

Designed to pack powders, dense, fine, loose and particulate materials as well as liquids and semi-liquids into 4-side sealed sachets and to accommodate different bag shapes including tear notches and easy-open system. They can be fitted with servo auger fillers &amp; volumetric fillers for powder applications, and two different liquid fillers for sauces or creams.

Sachet Machine

If you are looking to pack your product into stick packs from 17 x 40 mm to 100 x 200 mm in size, you may benefit from the experience from the largest manufacturer of stick pack machines in Europe.


<h2>Benefit from the experience from Europe’s leading producer</h2>
This multilane Stickpack Machine series (ST200, ST400, ST560, ST800, ST1200 ) by VikingMašek can accommodate a large variety of different shapes of stickpack pouches with high efficiency and flexibility.

The versatile multi-lane stick pack machines can accommodate from 1 to 20 lanes, running as fast as 80 cycles per minute.

They are designed to pack powders, dense, fine, loose and particulate materials as well as liquids into StickPack bags and to accommodate different bag shapes including pour spouts, tear notches and easy-open system.

Semi- or fully automated cartoning solutions are also available for individual or bulk cartoning.

Stickpack Machine

For bagging free flowing materials into open mouth bags, this system is ideal. It is a compact design, ideal for restricted packaging rooms and has a fully integrated gross or net weighing system.


<h2>Efficient bagger that fits into limited space</h2>
The Premier Tech Chronos OML SERIES open-mouth bagging systems are designed for bagging free-flowing materials into open-mouth bags for applications between 5 and 50 kg per bag. The systems are ideal for bagging flakes and granules from the Food, Feed, Pet Food, Chemicals and Minerals industries.

The OML SERIES features modular designs in three versions: compact open-mouth bagging system (OML-1080 SERIES, up to 800 bags per hour), high-speed open-mouth bagging system (OML-1120 SERIES, up to 1,200 bags per hour) and high-speed open-mouth bagging system for PE bags (OML-1120 FS SERIES, up to 1,200 bags per hour). Units can be supplied with either gross or net weighing systems for optimum system performance.

Open-mouth baggers for free flowing powders

Where a stand-alone bagger is required for filling large, open mouth bags, a delivery method is needed to dispense the product into the bag below before the closing stage.


<h2>Fill open mouth bags easily with standing bagger</h2>
The AP 300 series from Paglierani dispenses any type of material into an open mouth bag via a vertical screw compactor. This ensures consistent and continuous packing, being easily integrated into any production line.

Italian know-how is incorporated into the design, safe and strong enough for even the most aggressive environments.

Bagger for open mouth bags

Open mouth bags allow for a variety of different products to be packaged, with varying bulk densities and flow characteristics. Accurate weighing and bag delivery is required when automating this process.


<h2>Dose and fill open mouth bags automatically</h2>
Paglierani's COMBeI FS 368 series provides fully automated metering and filling of open mouth bags. As with all Paglierani designs, it is sturdy and suitable for aggressive environments and can be integrated easily into any production line before the bags are sewn, heat sealed or pinched closed.

With their Italian technology, Paglierani set the standards for small to medium scale bagging solutions for bulk products.

Automatic bagging machine for open mouth bags

A large range of sizes and types is available, with traditional horizontal form fill and seal machines being designed to produce and fill a single type. A modern, modular system allows a completely tailored solution, meaning no compromise on quality and speed of pouch production.


<h2>Flexible pouch filling machine that can be adapted for liquids, solids and powders</h2>
The BMK series from Bossar is a fully modular pouching system that has been designed to meet the requirements of the food, chemical, personal care, and cosmetic industries. From autoclave pouches for cooked foods, to shaped pouches with valves for liquids, and traditional single and twin sachets, the BMK series meets the needs of many producers.

The BMK series is built with a frame construction that comprises three independent and customisable modules: a film unwind module, a pouch forming module and a pouch filling module. Each is available in one of several versions, which allows you to specify the exact combination for a packaging solution that’s perfectly tailored to your requirements.

This flexible approach allows for over 35 different types of pouch to be produced by BMK series machines, included zippered, valved, and shaped pouches. Double film reels of up to 600mm diameter may be installed, reducing downtime between film changeover, and allowing pouch sizes up to 200mm x 300mm to be produced, with volume up to 2500cc.

A wide range of dosing units can be specified, allowing any type of product to be packaged by BMK. Options include insertion valves, volumetric fillers, auger fillers, multihead weighers, flowmeters, and more. Straws, valves or zip closures can be inserted into the pouches if required.

Construction and operational design has emphasised strength and reliability, with ease of maintenance and hygiene. A mechanical walking beam transport system gives reliability and a performance of up to 200 units per minute depending on pouch configuration.

For speedy format changes, the cutting device, gripper and servomotor film pulling systems are automatically adjusted from the HMI touch screen with only a single press, and all areas of the machine are visible and accessible through transparent hygiene covers for ease of operation, maintenance and cleaning.

Modular HFFS Machine

When producing cereals, it is paramount to stay on top of market trends. New packaging forms can be essential for successful marketing. A versatile convertible machine, allowing you to make use of different carton shapes can be invaluable. Like, for example, a continuous vertical cartoner.


<h2>Guiding the product into primary packaging</h2>
The Basis80, designed by Basis, is a vertical cartoner, that loads products from the top, for grocery products such as cereal, short pasta, oat flakes, nutritional yeast, soda and salt. A flat carton is taken by the magazine feeder, folded and then placed onto the conveyor belt into a vertical position. After the carton is placed on the conveyor belt , it is conveyed to the spot where it is filled with the product. Afterwards, one side of the box is closed with hot melt glue. The product is not pushed into the carton, but rather guided into the secondary packaging. The necessary  information like the manufacturing date is printed on the bottom outer flap. The top flaps are closed and sealed, before the packed end product is discharged from the machine.

The BASIS-80 works with a continuous motion and is easy to adjust, which allows to work with a wide range of pack sizes. Optionally, it is possible to install a vibrating table in the loading area which allows easier sealing of the product in a box.

Continuous vertical cartoner

When packaging products such as seeds, cereal, snacks, candies, nuts, tea, dried fruits and many other bulk or small products, a pillow bag is one of the most popular packaging choices. It saves on space, is light, easy to open, and most importantly – cost effective. For gaining the best profit, it is also important that a pillow bag machine is fast and flexible. A packaging machine that works at a good speed and uses pillow bags as a packaging form, is a great cost-effective fit.


<h2>Top loading the product in the bag and sealing it shut</h2>
The Basis17, designed by Basis, is a fast model for packing bulk production a so called pillow bag, gusset bag or stabilo bag.  The machine reaches a speed of up to 120 packs per minute. A pillow bag is formed from a continuous roll of packaging film and guided over a forming tube. Seal bars bond the film on the two long sides of the bag after which the shorter bottom side is sealed by a separate seal bar. The product is then loaded into the bag through a forming tube and once the bag is filled, the top of the bag is sealed as well. The long film that forms several bags is now separated by a knife to form individual bags. After this stage, the end product is discharged from the machine.

The Basis17 gives the opportunity to pack the product in a wide range of packages, including pillow, gusset and stabilo bag. It can be integrated with weighters such as a volumetric rotary, a volumetric auger, a weight vibration (linear) or a combination (multi-head) of types. It is possible to pack products in the weight range from 25 gram to 1000 gram.

Pillow bag vertical packing machine

Large-volume producers of single-serve packs, such as sugar sticks, instant coffee, and instant soup, continuously pack different product sizes into cartons. Intelligent and flexible infeed systems are needed to ensure your products integrate smoothly into the carton line at higher speeds.


<h2>Pack stick packs or flow packs into cartons continuously</h2>
The VENTO Cartoner from Mpac is a carton packaging system with a smart infeed system suitable for single-serve products such as condiments or coffee and milk powders. The unit is made of hygienic stainless steel materials. It has an open design for easy visibility of product flow and quick access to the components in case of maintenance and cleaning.

The entire system is servo-driven and coupled directly to its components for minimum maintenance and long operating life. It is designed to operate 24/7, allowing maximum production yield, and is equipped with an advanced intelligent machine interface that provides information on machine status, maintenance, and changeover controls based on product application. The processes include carton erecting, loading, transportation, and closing. Changeover for different carton sizes and types can be done quickly and automatically.

High-speed Cartoner For Single-Serve Products

Basically, to make milk powder, you need to remove the water content from the liquid milk and turn it into powder. How to do it? After pasteurizing and homogenizing the milk, milk’s water content is removed through filtration, evaporation, and drying. You have then to cool and sieve it before filling the containers. Here's how you get milk powder.

Milk powder

Mayonnaise is created by blending oil with eggs, and then flavoring with vinegar, mustard, herbs, and spices. The eggs are a natural emulsifier that creates a uniform mixture. Ingredients are pumped into mayonnaise manufacturing equipment. First, a dynamic mixer maintains the desired level of emulsification of the mixture, which then moves on to packaging and bottling once reaching a satisfactory consistency.

Mayonnaise 

Ketchup processing begins with tons of tomato paste that is mixed and heated together with sugar, vinegar, and spices in a cooking kettle. After cooking, any remaining fibers and particles are filtered out. Once it reaches the right viscosity, your tomato ketchup production process is finished and ready for packaging and transport.

Ketchup

White, black and brown seeds from the mustard plant are the key constituents of this colorful and classic condiment. The various mustard production technology includes a mixer that mixes the mustard seeds with a handful of other ingredients and a mill that finely grinds the seeds to impart their characteristic flavor.

Mustard

Mpac Group is an industry leader in packaging automation, cartoning, and case-packing technologies.

Its complexity begins with the term itself, which has no clear and precise definition in the industry. As Jan Verweijen and Frank Jeurissen from the Mpac Group explain, the big question is always: is it a sachet or a stick pack?

“What is what” is defined by the way it is sealed, not by its width or length. A stick pack is a product with three seals, one of which is in the middle, lengthwise. Instead, a sachet is a four-sided sealed product with no seal in the middle.

First introduced in Japan in the 70s to pack sugar, these single-use sticks are now used to pack everything you can think of. But what impact does your product have on the cartoning process?


<h2>The first step is to find the right balance.</h2>
Stick packs are first filled vertically; this means that all the product is on the bottom.

Before entering the stick packs into the cartons, you need to evenly divide the product over the left and the right side of the stick packs. This step is called equalization and it is done by horizontally shaking the product to redistribute the contents inside the sticks.

“<em>If the weight is not evenly distributed, all the stick packs will slide off toward one corner of the box leading to an unstable formation that can damage the sticks</em>.” Frank points out.

For mere mortals, powder is powder, but for the experts, coffee powder, for instance, has a different structure than cocoa powder.

“<em>Liquids do not need equalization as the fluids divide automatically.” </em>Jan explains.

In addition, the sticks must have a minimum size, usually around 80 or 90 millimeters, to be cartoned horizontally and the shorter the sticks, the more difficult to keep them stable.
<h2>On edge vs. random orientation - Which side do you stand on?</h2>
Premium single-use products, such as coffee or pharmaceuticals, are often packed with the brand name and description always facing the consumer.

“<em>When this is the case, we use a paddle conveyor that brings each stick pack on a single edge so that when pulled out of the box, the branded face is the first thing the consumer sees,</em>” says Jan.

Frank adds: “<em>In 90 percent of cases, manufacturers choose speed over where the stick pack is facing. With random orientation, you can easily speed up to 900 sticks per minute</em>”.

“<em>Our bomb bay system counts each stick individually and puts them together in the quantity the producer requires; then it drops the sticks into the bucket conveyor</em>.” continues Jan.

To prevent damage, the bomb bay system consists of multiple drop levels, and the sticks need to be always dropped at a limited height - no higher than 250 mm.

As every stick has two ends, cartoning single-serve packs may seem easy, but as Jan and Frank explained, the journey from equalization to orientation and bomb bay dropping is not exactly a piece of cake.

Unpacking the world of stick pack cartoning

Food

Pharmaceutical

With over one-third of the population consuming it daily in different forms, coffee is one of the most popular processed beverages worldwide. Not only serving as drinks, but coffee is also often regarded as a culture. Coffee manufacturing is a knowledge-intensive industry. Coffee beans from different regions will reveal different tastes, while the level of caffeine could also be different. When it comes to coffee bean processing, the range of roasts varies from light golden brown all the way to dark. The method of tasting coffee differs between countries, habits, and tools.

Coffee

Eating is more than just nutrition, but we have found ways to increase the nourishing power of our foods. Nutraceuticals manufacturing, from vitamin C powder and probiotics to omega 3 oil, is a concentration of natural ingredients and health supplements that complement our diets. While dietary supplements are not quite haute cuisine, the process of extraction and purification is no less a blend of science and art.

Nutraceuticals

Sauces bring personality to a dish. From a spicy, dense Zhoug to a tangy, runny Suero, sauces add an extra dimension of flavor, texture, and mouthfeel. But developing recipes into industrial products with long shelf lives and consistent tastes is a complex process. Specialized sauce making equipment prepares and combines the ingredients into delicious, high-quality foods. The result is a sauce ready to elevate meals.

Sauce

<span style="font-weight: 400">Spice manufacturing is one of the world's oldest trading products. The word spice refers to any dried part of a plant other than the leaves and is used for seasoning and food coloring. Spices are made from dried barks, roots, berries, and twigs, while green leafy parts of plants are considered herbs. Well-known examples include cinnamon, chilies, star anise, ginger, garlic salt, turmeric, cumin, or pepper, as well as pre-mixed blends such as Masala, Five-Spice Powder, or Old Bay.</span>

Spices

Find production technology for Sugar packing, and connect directly with leading machine manufacturers worldwide

Sugar packing

Which sugar packing equipment do you need?