With its new FPC6, Theegarten-Pactec is launching an innovative flow-wrapping machine specifically designed to meet the requirements of manufacturers of chocolate, confectionery, cereal and protein bars, functional foods and snacks, as well as co-packers and contract packers. The new development combines outstanding flexibility with advanced user-friendliness, digital networking and maximum process reliability. As a system solution, the FPC6 enables a fully automated packaging process.
With the FPC6, Theegarten-Pactec is specifically strengthening its expertise in flow-wrap packaging and presenting this innovative system solution for efficient packaging processes – from unpackaged products to secondary packaging in cartons – at this year’s interpack. The entirely new generation of machines doesn’t focus on the principle of ‘faster, higher, further’, but rather on stable, reliable and sustainable efficiency throughout the entire life cycle. With the new machine, the company is also implementing an automated system from a single source, which transfers the flow packs directly to the BLM high-performance cartoner developed in-house.
Outstanding flexibility for a wide range of products and packaging materials
The FPC6 reliably packs chocolate, confectionery, cereal and protein bars, functional foods and snacks into flow packs. It processes a wide variety of product formats without major retooling and masters several sealing types – cold sealing, heat sealing and cut-seam welding for water-soluble films. An integrated preheating section also enables the reliable processing of sensitive materials such as paper or recyclable mono films, even in high-performance operation. The FPC6 thereby offers maximum flexibility combined with consistently high packaging quality – a decisive advantage for manufacturers who are increasingly working with changing packaging materials and sustainable material solutions.
A new approach to operation: efficiency regardless of experience level
The FPC6 was consistently designed to make machine operation largely independent of the operators’ qualifications and experience level. Theegarten-Pactec’s goal is to enable customers to operate their systems independently, reliably and with a high degree of efficiency in times of skilled labour shortages. A key factor is the improved identification of error causes and their effects. Enhanced visualisations on the touch panel and graphic replacement images provide operators with targeted support in systematic troubleshooting, even if the cause and the fault are physically separated. For example, the machine recognises when faults at the machine outlet are caused by upstream process steps such as the synchronisation of unpackaged products. In such cases, the control panel specifically indicates possible sources. This reduces downtime and avoids unnecessary interventions.
Theegarten-Pactec also focuses on maximum user convenience and reproducibility when changing formats: all relevant settings are recorded electronically and stored in the recipe management system. Electronic counting scales ensure repeat accuracy during format changes; manual adjustments via trial and error are no longer necessary.
Simplified design for reliable processes
Theegarten-Pactec reduces additional sources of error with its well-conceived design. Critical components can be removed and cleaned without tools. All replaceable components are designed in line with the ‘poka-yoke’ principle (a Japanese method for avoiding errors in production and work processes), which prevents incorrect installation. The company also consistently simplifies product feeding. Instead of replacing the entire product lug chain – a time-consuming and error-prone process – operators can quickly and safely replace individual lugs of the chain when changing formats. This allows a format-specific arrangement to be created without removing the entire chain, ideally matching the packaging process to the product and packaging material. At the same time, mechanical stress is reduced – a decisive advantage with increasingly sensitive products.
The operating concept is complemented by transparently designed, well-lit functional areas. The shatterproof Makrolon cladding allows the degree of contamination of the machine to be seen at all times – for example, in the case of batch-related changes such as soft chocolate. Thanks to the transparency, the wear status of central components can also be detected during operation. Maintenance work can be specifically tailored to the actual condition of the system and implemented in a planned manner. This significantly reduces unexpected downtime due to undetected wear. Theegarten-Pactec is thereby creating the ideal conditions for proactive intervention and permanently stable processes.
