From concept to impact: a 6-lane sachet packaging line with smart easy-open features

Getting to grips with the challenge

The customer had an existing machine but wanted to convert it for a completely new application:

• suitable for both sealing and die-cutting sachets for food supplements,
• with a 6-lane production process,
• and fitted with an easy-open system, whereby the torn-off section must remain attached to the packaging.

In addition, the machine had to be quick to convert to other applications and – if necessary – easily reverted to its original standard function.

A challenging combination of mechanics, cutting technology, seal quality and flexibility.

Design of the comprehensive solution

As this was not just a matter of individual components but a functional comprehensive solution, we took a holistic approach to the project:

• analysis of the existing frame and filling lines
• determination of the space required for 6-lane processing,
• integration of sealing and punching functions into a single controlled movement,
• and the development of a modular concept to enable quick changeovers.

Development of interchangeable modules

A key component of the solution was the design and manufacture of the interchangeable sealing and cutting modules. :

• It was of great importance to the customer that these could be converted quickly, with minimal downtime and production loss

The modules were designed entirely for the customer’s specific sachet material. The product to be filled also has a very low specific gravity, which had to be taken into account. We have used the easy-opening feature on several occasions and it was integrated fairly quickly

Dealing with materials and low product weights

An additional challenge for us lay particularly in the properties of the packaging material used, combined with the very low weight of the end product.

This required the usual extremely precise cutting geometries, but also a specific design in which the relatively low weight had to be provided with a stable seal and the transport of the sachets was not to be delayed, thereby ensuring that capacity could be achieved.

Through multiple test phases and fine-tuning of the design, cutting pressure, temperature and timing, a stable, reproducible process was ultimately achieved.

Commissioning & Final Result

Following assembly and adjustment, the machine has been successfully commissioned. The customer now has a 6-lane sachet processing machine offering reliable sealing and die-cutting quality, with a perfectly functioning easy-open feature, and benefits from quick changeover options thanks to its modular design.