Meeting industry requirements

Torsten Bloch*

Pouches are in vogue all over the world – and according to experts are set to experience high growth in the future, too. There are many reasons for this. They are attractive to consumers and easy to handle and transport, for instance. This type of packaging, usually of film laminate, is also primarily popular with the food and non-food industries as compared to other containers, such as the can, PET bottle or carton, it needs less packaging material in relation to the volume it contains.  This not only cuts down on costs for materials but also for logistics and warehousing, in turn promoting issues of ecology which are further enhanced by the use of biopolymers. Horizontally arranged pouching machines are perfect for the production of especially high-quality pouches. KHS Bartelt has been active in this field since 1948 and has steadily continued to further develop its technology down the decades. To date around 4,000 KHS Bartelt pouchers have been sold across the globe. On its traditional US market KHS is still the clear number one manufacturer of pouching machines. The most recent KHS developments in this sector are the Innopouch K-400 and the Innopouch IMDG. The Innopouch K-400 is a linear machine in the K series with full servo assistance for demanding applications. It can run in both simplex (one pouch per machine cycle) and duplex (two pouches per machine cycle) operation. The Innopouch IMDG is based on the proven IM series for simple applications and has double-sided pouch grippers as opposed to the usual single-sided grippers. These enable large pouches to also be reliably and attractively formed, filled and sealed. Both innovations – like the other pouching machines in the KHS portfolio – profit from KHS' unequaled expertise. As an international manufacturer of filling and packaging technology KHS not only has production sites in the USA, Mexico, Brazil, China and India but also several factories in Germany. KHS provides turnkey systems for pouch processing worldwide and with over 60 service and sales points on all continents of the world is quickly on site when required.

*Sales Europe, Pouching Machines, KHS GmbH, Kleve, Germany. 

  Phone: + 49 2821 503130

Also a stand-up pouch pioneer

As one of the first manufacturers of horizontal pouching machines KHS Bartlet has also been a pioneer in the production and processing of stand-up pouches since 1974. KHS Bartelt pouchers can also manufacture all kinds of other pouch designs. The clear advantages of stand-up pouches or Doypacks are that they can be positioned on the store shelf without utilities such as hangers or secondary packaging, are attractive and eye-catching with effective promotional printing and thus signal added value for the product they contain in direct contact with the consumer. 

For dry products 

All kinds of dry products can be filled into many different varieties of pouch on KHS Bartelt pouching machines, from chunky products, like dry food for animals, herbal candies and herbs and spices to finely ground powders, such as baking powder or ground coffee. Whereas stand-up pouches are usually the packaging of choice for chunky, large-volume products, flat pouches are often used for powders. Especially where large amounts of product are to be packaged the bottom gusset pouch is a top seller, with said gusset providing a particularly high filling capacity. 

Numerous options 

Various options can be included in the pouches. These include tear-open aids, such as simple incisions or notches, zippers and sliders and different pouch shapes. KHS provides detailed advice on all opportunities open to the customer prior to any investment.  The film the client wishes to use on the machine and the products to be pouched are also tested on the designated dosing system at the KHS laboratory. Once tests have been concluded and all facts taken into account, KHS then provides information on the processing of the designated materials and data on the possible performance of the machine.

Horizontal machines for high precision

The market has both horizontal and vertical pouching machines on offer. KHS has always traditionally opted for horizontal technology; while vertical machines form, fill and seal the pouch around the filling tube, horizontal machinery operates in several cycles when manufacturing and filling pouches. This means that each individual stage in production (base sealing, side sealing, punching, etc.) can be fully concentrated on, ensuring very high levels of precision, outstanding pouch quality and appearance and top filling accuracies.  

Three poucher series for various industry requirements

KHS has three series of pouching machines in its portfolio for various areas of application. The Innopouch IM, for example, is a linear poucher for simple applications which is easy to operate and service and extremely reliable in its operation. It is equipped with single-sided pouch grippers and primarily used for smaller pouches. Despite permanent further development it's heralded as the 'original' poucher. This series has recently been expanded to include the Innopouch IMDG which has all the benefits of the IM series but is kitted out with two pouch grippers instead of one. These can be quickly changed over when new pouch formats are scheduled. This provides even greater precision when sealing the pouches and as a result also enables larger pouches to be processed.  On the IM series the present maximum pouch height is 240 mm; the Innopouch IMDG can now make pouches that are up to 280 mm high and 200 mm wide. In 1991 KHS introduced the Innopouch RPM specifically for companies who only have a small production area. This machine has a compact design and fills and seals pouches on an eight-station rotary machine. It can be run in both simplex and duplex operation. Where the IM (including the IMDG) and RPM series consist of classic mechanical machines driven by vertical shafts and cam disks, the K series launched in 2008 has full servo control and thus maximum flexibility and very fast changeovers. The most recent development in the K series is the linear Innopouch K-400 machine which has simplex and duplex operation.

New, modular Innopouch K-400

The Innopouch K-400 is available as an FS (fill and seal) and an FFS (form, fill and seal) machine. The FS machine is supplied with prefabricated pouches from a pouch magazine; the FFS machine, on the other hand, both makes and fills the pouches.  As the poucher is modular in design, if a customer opts for the FS version, he or she can later have it expanded and converted into an FFS machine if required. 

Hygienic design

Special attention was paid to the hygienic aspects of the Innopouch K-400 during its design development. Thanks to the open design, there are no mechanical components under the pouch grippers that have to be extensively cleaned. In the machine housing spacers are used in place of the usual rubber seals to prevent powder or product residue from accumulating. This makes the machine quick and easy to clean. The film dispenser is also fully enclosed for reasons of hygiene. Where powder products are scheduled for filling, one recommended option is to separate the pouch forming and filling areas by a pane with a cutout through which the packs are conveyed. Another big plus is that the frame of the Innopouch K-400 is made entirely of stainless steel. This not only increases hygiene but also helps ensure a long service life for the system. 

Simplex and duplex processing 

The Innopouch K-400 can process a wide range of packages (stand-up, flat and bottom gusset pouches). In simplex operation these may have a width of 125 to 400 mm and a height varying between 125 and 380 mm. They can weigh up to 2.3 kg. All that changes in duplex operation is the width which is reduced to a maximum of 200 mm. The Innopouch K-400 can run at up to 70 cycles a minute. The use of linear servotechnology especially has greatly simplified and shortened what used to be time-consuming changeovers from simplex to duplex operation and vice versa. Most format changeovers are now made on the operator panel at the push of a button.

Pouch forming process

The Innopouch K-400 operates as follows. Flat roll stock is fed from a reel of packaging material through a dancer system to the plow. A number of plows are used to make flat, stand-up pouches or bottom gusset pouches with their various gussets, all of which can be quickly and easily changed over. The sealing station not only seals the bottom and side fins but also performs options such as the application of zipper or slider seals. A quick-change sealing system ensures fast changeovers when processing different pouch formats. Controlled cooling of the processed pouch fins takes place in the cooling unit downstream of the sealing station. This is done so that no threads are formed in the cutting unit when the pouches are separated from the endless tube. 

As the Innopouch K-400 is modular, there are many pouch forming options which can be integrated into the aforementioned basic modules. These include a punch system for contour pouches, for example, and additional sealing tools or equipment for applying tear-off aids, etc. New pouch formats and capacities can also be realized at any time should these be required. Customers can also have extra modules incorporated into the system as retrofits. Companies are thus on the safe side with the Innopouch K-400 should demands change at the plant. 

Gripper systems for precision conveying

As in the pouch forming section, the filling segment of the Innopouch K-400 can also be supplemented by new modules at any time. The pouches are conveyed to the filling area by transfer grippers.  In the filling system each pouch is held on both sides by a double-gripper system. The pouches are conveyed by just one pair of grippers right up until they exit the Innopouch K-400. There are no transfers, thus ensuring high positioning and filling accuracies. The grippers move when the pouch is opened, with suction elements simultaneously supporting this process. When stand-up pouches are processed, the base is formed in the pouch forming station.  To this end classic or filtered compressed air or protective gas is used depending on the product, the latter for very sensitive products which do not tolerate oxygen. 

Precision dosing of the components

There are a standard four filling stations on the Innopouch K-400 which can be added to as an option. The advantage of dosing stations connected in series is that the individual components or ingredients are dispensed into each pouch in the correct order and specified amount. This cannot be ensured when filling a mixture of components (segregation problems). Take dry soup, for instance; the first station could dispense powder, the second dried herbs, the third croutons and the fourth noodles. 

Volumetric or gravimetric filling process?

The dosing systems are always selected according to the product to be filled,  with both volumetric and gravimetric systems possible. Volumetric filler types include auger fillers, table feeders and sliding gate fillers. Where auger fillers are usually used for powdery products, such as baking powder, flour and ground herbs, etc., table feeders and sliding gate fillers are perfect for larger products like rice, croutons, peas, dried fruit and so on. A tendency controller in conjunction with a belt weigher can support the exact filling tolerance of each product by volumetric dosing systems.  For expensive products especially, gravimetric filling systems such as multihead weighers are frequently used, the reason being that they achieve very high dosing accuracies. Compared to volumetric systems, however, the investment costs are considerably higher. 

Thermal sealing versus ultrasound sealing

Once they have been filled, the tops of the pouches are then sealed. This usually involves a thermal sealing process. Ultrasound sealing is also an option here. This also seals through any product which may still be in the closure area, thus always ensuring that the pouch is tightly closed. The disadvantage of this method is that it calls for a higher investment. To avoid this optional knocker and vibrating devices can be positioned upstream of the thermal sealer which ensure that there is no product residue at the top of the pouch during sealing with a broad spectrum of products. 

Linear servotechnology for fast format changeovers

Fast changeovers in the filling area of the machine are also a given on the Innopouch K-400. Where the pouch grippers are still held by chains in the classic Innopouch K series, the Innopouch K-400 works with linear servomotors. As a result the individual pouch grippers can be positioned at the press of a button on the operator terminal, adjusting themselves to new pouch widths as quickly as they switch  between simplex and duplex operation.  Linear servotechnology also permits continuous operation of the grippers and thus the pouches as opposed to the intermittent operation common to date. 

Turnkey system possible

As a turnkey supplier KHS can also pack products into cartons once the pouches have been formed, filled and sealed. For this purpose it has a range of intermittent (outputting up to 70 cartons per minute) or continuous side-loading cartoners (with a maximum capacity of 500 cartons per minute) which can flexibly process various shapes and sizes of carton at varying speeds and which also feature quick and easy format changeovers. The cartoners are not just perfect for use with products packed into pouches but also for frozen food, cosmetics, candies and tobacco goods, for instance. KHS also manufactures the necessary auxiliary equipment needed to make the cartoning process a success. For example, a grouping station places products on top of or next to one another with absolute precision, with the downstream pocket conveyor synchronously feeding products into the cartoner which then gently pushes them into the box from the side. The grouping stations and conveying systems are tailored to suit the application on hand with the benefit that there are no interface problems; KHS provides turnkey systems as a one-stop shop and is therefore the sole contact and supplier. 

KHS also offers various options for gentle carton palletizing; column or articulated robots are selected entirely depending on the packs to be processed, the line capacity and individual customer requirements. The result is a packaging line which has been created in full accordance with customer specifications.

Remote maintenance if service is required

If service should be required at any time, 

KHS has a remote maintenance facility for all Innopouch models and KHS cartoners and palletizers.  Online assistance involves accessing the central intelligence in the machine controller, upon which immediate remote analysis takes place. Ideally, setting up online access to the electronic system components is usually enough to solve the machine problem in question. If the problem involves mechanical components, the engineer at the machine is notified as to which exact actions must be taken. 

Giving the industry what it wants

All told, with the newly developed Innopouch IMDG and Innopouch K-400 KHS is giving the industry the systems it wants. While the Innopouch IMDG is first and foremost the consistent further development of the existing IM series which satisfies the requirements of the food and non-food sectors for a robust, reliable, mechanical machine with shorter changeover times, with its linear servotechnology the Innopouch K-400 stands for minimum format changeover times, maximum flexibility and thus very high line efficiency and operator friendliness. Even if consumer demands change, this is a system which is well equipped for future eventualities.