Packaging specialist Theegarten-Pactec makes high-speed packaging possible with paper-based flow packs which can be fully recycled in the paper waste stream and reused for new applications.
Theegarten-Pactec has developed the ideal solution for heat sealing paper-based packaging – in the high-performance range. Where speeds of 80 to 120 m/min are otherwise possible for conventional films in this range, an impressive 90 m/min is achieved for the paper-based packaging material on the FPC5. This corresponds to 600 sizeable 40g chocolate bars per minute.
Thanks to this solution, the machine can now produce a flow pack package made of barrier paper with integrated heat-sealing capability and a pure paper content of at least 95%. Due to the low proportions of sealing material and barrier layer against grease penetration, moisture or other environmental influences, the packaging produced can be fully recycled in the paper waste stream and reused for new applications.
Specifically, optimal processing of paper-based packaging on the FPC5 is achieved by precisely preheating the longitudinal sealing and cross-sealing areas of the paper. In this way, the paper reaches a higher initial temperature in selected places before the chocolate bars are packaged and heat-sealed. This appreciably reduces the amount of time for which heat must therefore be applied to the paper via the sealing tools during the actual sealing process to achieve the optimum sealing temperature. Thanks to this shortened sealing time, the high speed of 90 m/min can be achieved. In order to protect the sensitive packaging material, Theegarten-Pactec has also proactively adapted the sealing profile or the sealing jaws to the paper material to achieve a perfect match. Adjustable heating temperatures allow the process to be optimally adapted both to the requirements of the packaging material and the characteristics of the product to be packaged. This prevents damage to the packaging material and product and ensures that both are processed with particular sensitivity by the machine.
And the special nature of the sustainable packaging material was also taken into account in another area: Theegarten-Pactec has modified the forming shoulder for the production of paper-based form-fill-seal bags on the FPC5. Due to the material used and the geometry adapted to fit the packaging material, there is no risk of the paper creasing or even tearing during the formation of the flow pack.
Theegarten-Pactec has even taken the packaging process with the sustainable material a step further. For example, the FPC5 is equipped in such a way that so-called “gusseting”, i.e. indentation of the packaging material at the cross fin, can be easily accommodated with the paper packaging, ensuring that the paper does not tear at this point either. This allows a straight packaging end to be formed from paper. A wide cross fin, which would make it difficult to pack the chocolate bars in further, secondary packaging and would take up unnecessary space, is thus effectively avoided. With the BLM cartoner, Theegarten-Pactec can also supply the right machine for secondary packaging in cartons. The cartoner is designed to fit perfectly with a primary packaging machine in the high-performance range. The combination of horizontal form, fill and seal machine and cartoner thus enables efficient primary and secondary packaging using paper-based packaging materials.
If you would like to experience the new solution as well as the performance of the FPC5 packaging machine, you can see for yourself on Theegarten-Pactec’s Youtube channel: https://youtu.be/b82YVPMOm7M
Image credit: Theegarten-Pactec
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Editor, International Confectionery
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