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| November 11, 2025 | Volume 21 Issue 42 |
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Motion Applications: Max performance for pouch-filling machines
FAULHABER drive technology brings dynamics, precision, and high availability in the tightest spaces for packaging machines from Scaldopack.
Scaldopack system for inserting closures and filling pouches. [All images courtesy of FAULHABER]
Speed is of the essence for packaging machines: Products must be filled, reliably sealed, and prepared for shipping in the shortest possible cycles. Moreover, if food is being packed, the hygiene requirements are also high.
To keep the total cost of ownership (TCO) low, maintenance should rarely be necessary, and unplanned downtime should avoided. The list of requirements is, thus, long and applies not only for the packaging machine itself but also for the components that are used, such as the drive technology. This article describes pouch-filling machines that are used to pack both high-viscosity foods and non-foods as well as products with particles.
Food products such as dips and hummus can be packaged in pouches, as well as non-food products such as gels, shampoos, and lotions.
At the same time, flexibility is also very important. Scaldopack systems can easily be converted from one batch to the next in a short time. Depending on the system and application, changeover times range from just a few hours to less than 30 minutes in some cases. Moreover, all systems are constructed so that maintenance is rarely necessary and can be performed quickly. This also serves to keep the TCO of the machines low.
Filling foods and non-foods
Scaldopack offers a number of systems: several pouch-filling machines and spout-inserting machines, which insert the pouch closures into pouches of various sizes. The filling machines differ in terms of throughput, i.e., how many containers can be filled per minute and the type of the filled container. The Smartfiller Ecoline, for example, is notable for its flexibility. In addition to pouches, it can also fill bottles and containers. The Monofiller Multihead 4, on the other hand, can output 120 packages per minute thanks to its multi-head capability. Both foods and other high-viscosity products, or products with particles, can be filled. Typical non-foods include gels, shampoos, lotions, soaps, conditioners, cleaning agents, plasticizers, auto oils, and adhesives. Among the classic foods that can be filled with the system are baby foods, dips, hummus, sauces, peanut butter, honey, yoghurt, juices, and alcoholic beverages. Manufacturers of sport gels, for example, also use systems from Scaldopack. These sport gels are used primarily by endurance athletes who need to perform at a high level and require a targeted, fast supply of energy and a reliable electrolyte balance.
Detail view of the packaging system.
The packaging machines, themselves, need to perform at a high level. They often work around the clock, seven days a week. Breaks for maintenance, whether planned or unplanned, quickly become costly and, thus, need to be avoided. Anyone purchasing such a system also always has an eye on the TCO. In addition to the acquisition costs, there are also maintenance costs, the need to maintain production quality, and the avoidance of variables that can contribute to production errors. What applies for the system applies for the installed components. High performance is demanded, especially, of the drive technology that is used.
Direct linear drives with built-in Hall sensors
For smooth and efficient operation of the machines, Scaldopack uses BLDC motors from FAULHABER. The direct linear drives with built-in Hall sensors enable a position accuracy to 0.1 mm with an acceleration to 4 g. This allows the pouches to be moved both quickly and precisely to the proper filling position. There, they are filled and sealed with the correct quantity of material and then stacked in displays for shipment or sale.
BLDC motors from FAULHABER with built-in Hall sensors quickly and precisely move pouches to their required position.
Because floorspace in production facilities is often expensive and, thus, limited, the filling systems also need to occupy as little space as possible. In the compact machine, it is advantageous for the drive unit to have minimal installation space requirements. With a volume of 22 x 22 x 74 mm, it still achieves a peak force of 27 N and offers exceptional long-term reliability. Unlike conventional pneumatic components, it can operate continuously for nearly three years without maintenance. This fits in very well with the goals of the equipment manufacturers to offer systems with low maintenance requirements.
The MC 3603 motion controller performs the drive control and communicates with the automation system.
In addition to the reliability of the drives, system integration and operability of the machines are also decisive factors. Highly dynamic MC 3603 motion controllers perform the position control. Using standardized communication interfaces such as RS232, EtherCAT, or CAN, set points for control can easily be selected, or the drive can be integrated in the automation system.
In the Scaldopack applications, the CiA402 compatibility of the motion controller enables simple integration in the EtherCAT control system of the filling system. The motion controller significantly simplifies not only the integration but also the necessary tests. This allows drive systems and machines to be optimally matched to one another to achieve peak performance.
These applications make clear what a decisive role dynamic, precise, compact, low-maintenance, and easy-to-integrate drive technology plays in the automated packaging industry.
FAULHABER specializes in the development, production, and deployment of high-precision miniaturized and miniature drive systems, servo components, and drive electronics with up to 200 W of output power. This includes putting into effect customer-specific packaged solutions as well as an extensive range of standard products, such as Brushless Motors, DC-Micromotors, Encoders, and Motion Controllers.
Source: FAULHABER
Published November 2025
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