Cup Filling and Sealing Machines
24. September 2018

Form-Fill-Seal
Machines

Competitive advantages due to creative cup designs

The four standard types of FFS machines proposed by Finnah cover an output range of up to 200,000 cups per hour. The machines can handle all currently available cup and lid films without any problems and can optionally be retrofitted by machine-integrated decoration systems.

The form-fill-seal machine combines years of experience with future-oriented engineering at a high performance level:

  • Variability thanks to a modular structure.
  • Latest servo-technology supports the flexibility.
  • Optional, integrable decoration systems enhance the appearance of the cup and thus support the attractiveness of the product at the POS.
  • Various Hygiene concepts up to full aseptic systems.
  • Sophisticated cleaning and sterilisation systems to increase the effective production time.
The main functions are subject to steady, technical developments whereby the gentle product handling, the maximum material economy and the environmentally sound level of energy consumption are always focussed.

    1. Forming
    The film is heated gradually using contact heatings and formed by means of pre-stretching rods and sterile air. The automatic start permits a low waste material use.

    2. Filling
    All fluids and high viscous products – even those containing solid substances – ca be dosed gently and precisely.

    3. Sealing
    Film related parameters, such as heat, sealing duration and sealing pressure can be set individually. Standard print markers and process controls guarantee an exact sealing of lids to cups.

    4. Cutting
    Single cups or cup sets are cut using modern, low-wearing, high-precision cutting technology.

The standard machines are technically high developed and still leave plenty of scope to cater for individual requirements with respect to cup shape and decoration.

Especially for the FFS machines we offer support in cup design. Such cups can then be safely produced on a FFV machine, since film properties and thermoforming ratios are taken into account in connection with cup geometry and volumes.

The four standard types of FFS machines proposed by Finnah and defined by the different widths of cup foil material make it possible, depending on the dimensions of the cups, to cover an output range of up to 200,000 cups per hour.
Leistungsdiagramm-Form-Fuell-Verschliessmaschine-EN
Type 2209 Type 2408 Type 2608 Type 2908
Minimum film width (mm) 350 650
Maximum film width (mm) 310 500 680 950
Maximum forming depth (mm) 110 110 110 110
Machine width (mm) 942 1330 1480 1730

Depending on the defined product characteristics as well as the selected distribution channel and the desired minimum shelf life, the „correct“ clean room technology of the machine is determined and thus a hygiene class. The hygiene classes applied by us comply with those defined by the VDMA (German Engineering Federation) and have to meet defined demands on machine an process technology.

According to the product and other conditions imposed by the environment, the FFS-machine can be designed in open, ultra-clean or aseptic versions. The choice of the corresponding sterilisation system to be used is made according to the product and packaging materials to be handled. The bacteriological reduction rate of up to log 5 is confirmed regularly by independent institutes.

The actual packaging material sterilisation takes place in FFS machines either by H2O2 baths or by the H2O2 spraying method. An important advantage of the spaying method is that the so-called „lotus“ effect is avoided.

Additional possibilities offer the sterilisation by means of UV-C radiation or pulsed light whereby aseptic filling with these systems cannot (yet) be achieved.

In order to protect the sterile packaging material and the product to be filled against the contaminated ambient atmosphere, the machines are protected with a tunnel from the film infeed up to the completely tight closure by heat sealing. In the tunnel directed sterile air flows prevent a recontamination by ambient air.

Procedural parameters such as consumption of H2O2, reaction times, temperatures etc. are continuously recorded by the operation and machine data acquisition and can be readjusted at any time if required. For known packaging material preset parameters are stored in the recipe Management.

The dosing procedure is a process that involves the interplay of exact mechanical precision and perfectly coordinated servo and automation technology. Finnah achieves this with three established systems that are always kept up to date:

  • Piston-valve doser
  • Piston-pipe doser
  • Doser based on iductive flow measurement

All types of free-flowing and highly viscous products, also with particles like fruit pieces or pulp in fruit juices, can be filled gently and specifically; hot or cold filling is neither a problem. On a simple touch of a button, the patented servo-driven filling system allows unique and reproducible filling patterns and variations. Furthermore, special dosing nozzles are available for different dosing applications, which are specially selected depending on the product and dosing pattern.

The simultaneous filling of different flavours or the dosing of different layers in one cup as well as a cream topping belongs to the standard repertoire. Finnah dosing systems are CIP and SIP capable and low maintenance by design.

Furthermore Finnah dosing systems also help to increase the valuable productive core time:

  • Sterile water supply being independent from the process
  • Nozzle changes can be performed by way of a fast-change mechanism

Our own material selection for all product-contacting machine components ensures that the product to be filled retains its specific properties during the filling process.

Finnah’s powerful decoration systems are designed as retrofittable, integrated machine components.

When using an in-mould-system the decoration is placed in the mould during the actual cup forming, so that the cups can then be moulded into the decoration. The previously heated cup film heats the hot-melt coating of the decoration and thus adheres to the formed cups.

Available are:

  • Banderole Labels from a role - also for conically shaped cups
  • Side Labels from a magazine or role
  • Bottol Labels from a Magazine or role
  • L-shaped Labels from a role

One highlight is the integration of a sleeve unit into a form-fill-seal machine between the cutting station and the discharge conveyor. Both single cups and cup sets can be sleeved.

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