Theegarten-Pactec – hot on paper

High-speed sustainable packaging possible with paper-based flow packs 

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Theegarten-Pactec has refined its FPC5 – a modular high-performance packaging machine for bars in flow packs – so that it can now process paper-based packaging materials Photo: Theegarten-Pactec
Theegarten-Pactec has refined its FPC5 – a modular high-performance packaging machine for bars in flow packs – so that it can now process paper-based packaging materials Photo: Theegarten-Pactec

Dresden-based Theegarten-Pactec presents a further development of its proven, modular high-performance packaging machine FPC5 for the packaging of chocolate products in June 2021. This machine makes it possible to process paper-based flow packs using the heat-sealing process in the high-performance range of 90 minutes a minute. 

Sustainable packaging has to be the buzzword in the packaging industry. For example, a recent online survey conducted by management consultants Simon, Kucher & Partners in March 2021 (Sustainable Product Packaging, Simon, Kucher & Partners, March 2021) revealed that for almost three-quarters of the consumers surveyed, sustainable packaging is a significant issue. In addition, consumers rated paper as a particularly sustainable material, 70% of them seeing it as an alternative to conventional materials. 

Consumers and brands are demanding sustainable packaging

Not only does this increase the pressure on brand manufacturers to offer appropriate solutions, but the packaging industry also has to step up to the plate. It must respond to the wishes of consumers, retailers, and, not least, to the requirements of legislators with resource-saving materials and processes and use sustainable packaging wherever possible. This is a trend that is naturally also being taken up by the manufacturers of packaging machines. 

Theegarten-Pactec, the packaging specialist for small confectionery, has long been aware of this trend towards sustainability. For example, it developed material-saving wrapping methods and optimized its machines for processing, particularly thin films. Now Theegarten-Pactec goes one step further with the FPC5 – a modular high-performance packaging machine for bars in flow packs – refined so that it can now process paper-based packaging materials. Thus, on the one hand, the common cold sealing process, and on the other, by far more complex heat-sealing process.

Heatsealing on Theegarten-Pactec
Theegarten-Pactec has developed a solution for heat sealing paper-based packaging – in the high-performance range. This enables an impressive output of 90 meters a minute to be achieved on the FPC5. This corresponds to 600 sizeable 40-gram chocolate bars a minute. Photo Theegarten-Pactec

Theegarten-Pactec has developed a solution for heat sealing paper-based packaging – in the high-performance range. Where speeds of 80 to 120 meters a minute are otherwise possible for conventional films in this range, an impressive 90 meters a minute is achieved for paper-based packaging materials on the FPC5. This corresponds to 600 sizeable 40-gram chocolate bars a minute. 

With 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%. Moreover, 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.

A flow wrapper sensitive to paper-based heat sealable substrates

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. For this purpose, the sealing area is already preheated during the unwinding process. Thanks to a technically sophisticated pre-drawing section, the paper does not deform during this step. In this way, the paper reaches a higher initial temperature in selected places before the chocolate bars are packaged and heat-sealed. 

The preheating of selected areas 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, a high speed of 90 meters a minute can be achieved. Theegarten-Pactec has also proactively adapted the sealing profile or the sealing jaws to the paper material to protect the sensitive packaging material achieving an excellent match. 

Adjustable heating temperatures allow the process to be optimally adapted to the requirements of the packaging material and the characteristics of the product to be packaged. In addition, this prevents damage to the packaging material and product – enabling both to be processed with particular sensitivity by the machine.

The special nature of the sustainable packaging material was also taken into account in another area by modifying the forming shoulder to produce 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.

Further, the FPC5 is designed so that gusseting (the 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 formed from paper. A wide cross fin would make it challenging to pack the chocolate bars in secondary packaging and take up unnecessary space.

With the BLM cartoner, Theegarten-Pactec can also supply the right machine for secondary packaging in cartons. It is specially designed to fit perfectly with a primary packaging machine in the high-performance range. Photo Theegarten-Pactec
With the BLM cartoner, Theegarten-Pactec can also supply the right machine for secondary packaging in cartons. It is specially designed to fit perfectly with a primary packaging machine in the high-performance range. Photo Theegarten-Pactec

Theegarten-Pactec also supplying machine for secondary packaging in cartons

With the BLM cartoner, Theegarten-Pactec can also supply a suitable machine for secondary packaging in cartons. The cartoner is designed to fit with a primary packaging machine in the high-performance range. The combination of horizontal form, fill and seal machine, and cartoner enables efficient primary and secondary packaging using paper-based packaging materials.

With Theegarten-Pactec’s patent-pending solution, manufacturers in the confectionery industry can now offer the perfect response to consumer and trade demand and score points with sustainable packaging alternatives.

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 . Theegarten-Pactec is represented in India by Pune-based Vedic Pac Systems.

(This article has been edited by Naresh Khanna.)

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