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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.
‘Flying splice’ and web edge control ensure process reliability at 150 m/min
The consistency with which this simplified operating concept has been implemented is especially evident when changing packaging materials. Optimised packaging material handling is a key factor in ensuring high system availability. Typically, the packaging material has to be changed every 20 to 30 minutes during the packaging process, which is why the packaging material unwinding of the FPC6 has been optimized.
The so-called ‘flying splice’ technology eliminates the critical steps that were previously required, such as precise threading and sticking on a double-sided adhesive strip. A roll prepared with adhesive tape is simply placed on the machine; no further steps or special precautions are necessary. Correct positioning, alignment and feeding are then carried out automatically. Furthermore, roll changes can be carried out without reducing speed, even at packaging speeds of 150 m/min. ‘Flying Splice’ increases both process reliability and system availability with minimal training requirements.
The FPC6’s web edge control also allows the course of the film web to be adjusted directly on the HMI (human-machine interface) – for example, depending on the batch or when changing flavours. Old and new values are automatically stored in the recipe management system. Manual settings that were previously necessary are no longer required, and the original target value is retained.
Reduced footprint by delivering more performance in less space
Theegarten-Pactec also follows a clear efficiency approach when it comes to installation space. The FPC6 combines high output with a compact design. Despite its performance range, it requires a significantly shorter product feed and takes up less installation space overall than previous machine generations. The compact design is the result of Theegarten-Pactec’s many years of engineering expertise. At an early stage, the machine configuration is precisely tailored to the products to be processed later. This is based on comprehensive tests with original products, which provide a reliable picture of the subsequent process behaviour. This ensures maximum process reliability right from the start. Product speeds of up to 100 m/min can be reliably achieved on this basis.
Additionally, the integrated control cabinet further reduces space requirements. All electrical and electronic components are integrated at the rear of the machine, eliminating the need for a separate footprint. Theegarten-Pactec customers benefit from greater performance per square metre, easier integration into existing lines and greater flexibility in production planning.
Flexibility in sealing – quick changes, precise adjustment
When it comes to sealing equipment, Theegarten-Pactec prioritises reduced complexity and maximum user-friendliness. The cross-sealing unit can be replaced without tools, guided and largely automatically via the HMI, and can be carried out using a conventional manual pallet truck. Specialised and often expensive transport equipment is not required. When the new sealing unit is inserted, a forced guide ensures automatic centering. The machine automatically recognises the cross-sealing device that has been inserted and connects all mechanical and electronic components with each other. All settings are stored in the recipe management system and are loaded as target values. This enables fast, reliable and reproducible format changes.
The FPC6 also masters a variety of sealing types – cold sealing, heat sealing and cut seam welding for water-soluble films – offering maximum flexibility in the choice of packaging materials. An integrated preheating section ensures that even sensitive materials such as paper or recyclable mono films can be processed reliably and with consistent quality. The sealing pressure of the longitudinal sealing unit is conveniently adjusted electronically via the HMI.
A clutch-based drive system for the transverse sealing unit ensures additional process stability. The manual gear readjustment that was previously necessary when changing the sealing gap is no longer required, which significantly reduces wear and increases component longevity. At the same time, the quality of the seal seam remains permanently stable, regardless of the readjustments that were previously often omitted. The seal gap can be adjusted in a fully reproducible manner, so that consistent sealing results are achieved at all times. Time-consuming, repeated readjustments during format changes are now a thing of the past.
Consistently precise print image positioning thanks to HMI-controlled film tension
The FPC6’s packaging material unwinding system is also designed for maximum process stability and ease of use. The tension of the film tube at the forming shaft – i.e. where the film is formed around the product – can be conveniently adjusted via the HMI. Excessive tension can cause the film to stretch and then contract again during the subsequent packaging process. Similar to a stretched rubber band, this shifts the print image position: the film is no longer cut exactly at the intended location, and the print image appears off-centre.
To prevent this, the FPC6 features automatic print image control in the longitudinal seal. In this area, the packaging material is already ‘relaxed’, so that a sensor can reliably detect whether the print image position is still correct. In the event of deviations, the operator can finetune the film tension directly on the HMI – quickly, reproducibly and without mechanical intervention. This is especially relevant when new batches of the same packaging material behave differently or when environmental influences such as temperature and humidity change. Even paper-based packaging materials, which are more prone to creasing, can be optimally adjusted in this way.
Everything from a single source – automated and networked
The FPC6 is designed both as a stand-alone solution and as part of an integrated system solution. The flow packs can be transferred directly to the high-performance BLM cartoner. From the unpackaged product to the carton, everything comes from a single source: including distribution systems, storage and feed components. The entire process is fully automated without the need for manual intervention. This increases hygiene and process reliability, reduces personnel costs and minimises interface risks within the line. Manufacturers benefit from clear responsibilities, high efficiency and maximum plant availability. The FPC6 can also be integrated into higher-level production and maintenance concepts via the SweetConnect digitalisation platform. Predictive maintenance and Industry 4.0 functionalities ensure transparency, increase planning reliability and guarantee long-term cost-effective production.
