Packaging machines for your food products
Member of Only experts master future technologies Challenges? That´s what we like.
Innovative packaging machines demand a high Life Science. Continuous growth has characterized level of specialization. Optima meets this require- this family business since it was established in 1922. ment with innovative concepts for the development With more than 1,700 employees worldwide, Opti- and manufacture of branch-oriented systems in its ma has deliberately chosen to maintain flexibility four areas of Consumer, Nonwovens, Pharma and and customer focus as central principles.
Food Single Serve Cosmetics Chemicals
Day after day, unimaginable quantities of prime advantages. From starter models to Consumer machines are also continuously food, cosmetics and chemical products are complete lines, including some with hand- optimized with respect to the total cost of dosed, filled and packed. Many of them ling and assembly functions. ownership. Thus they require only a mini- with machines from Optima Consumer mum of service, wear and tear and replace- and this for several reasons: machine flexi- Optima Consumer offers everything that ment parts while offering long-term high bility, high output rates, product protec- makes dosing, filling and packaging easier, performance and precise and consistent tion and process assurance are safer and even more economical. Optima weighing results.
2 Contents
4 – 5 For classic food products and innovations
6 – 7 Instant products
8 – 9 Soups & Sauces / Spices - dry
10 – 11 Soups & Sauces / Spices - liquid
12 – 13 Concentrates
14 – 15 Single Serve – capsules and pods
16 Secondary packaging
17 The SoftCan®Maker
18 – 19 Functional Closures
20 Service Lifecycle
21 Your contact partner
22 An overview of OPTIMA consumer
23 Addresses worldwide
3 For classic food products and innovations From large packs to portion packs
Packaging technologies for foods
Optima Consumer is your partner for packaging foods of varying regarded as extremely reliable, precise and with high output rates. consistencies: from thin liquids to pastes and for powders, granu- Whether semi-automatic single machines, fully automatic mono- lates and chunky foods. Optima packaging technologies are based block machines or complete turnkey lines, Optima has the solu- on decades of experience and are convincing again and again tions especially tailored to meet your needs. with innovations that set the standards in the branch. They are
Product characteristics Containers Closures ffLiquid ffGlass ffScrew closures ffPasty ffPlastic ffPress-on closures ffPowdery ffComposite paper ffPump closures ffGranulated ffFoil ffCrimp closures ffIn pieces ffMetal ffSeals
Machine Types ffPilot systems, sample production ffMonoblock machines (filling and closing on one machine) ffSemi and fully automatic machines ffComplete turnkey lines ffPackaging systems for portion packs
4 The best solution for every requirement
The processes ffContainer feeding ffFilling / Dosing ffLabeling ffDepalletizing ffClosing ffHandling ffCleaning / Sterilizing ffWeighing ffEnd of Line
mg – kg ml – l up to
5 Instant products
up to 400 containers/min.
Figure shows an example: OPTIMA MMK-FS
This is what matters ffCalibratable weight controls ffContainer sealing ffEasy access ffExplosion-protected machine execution ffCompact construction ffDosing with highest accuracy
6 Instant products
The processes for instant products
Cleaning of containers Closing ffAir rinsing, evacuation, turning and sterilizing ffScrewing, press-on, position orientation, crimping ffSealing: Inductive, ultrasonic, thermal Dosing ffAdjustable speed and torque ffVolumetric system ffClosure inspection with rejection ffGravimetric system ffVacuum system Handling ffAutomatic change of product Filling ffSimple and quick format changes ffCareful filling of product with cup dosing system ffCentral controls of the technical units or auger dosing machines ffInterface to a higher-level data system (MES/SCADA) ffDust-free filling process ffTouch panel ffVibrating stations increase product density and output ffRevolving funnels Further processes ffIn-line gassing ffArrangement of container groups ffVolume adjustment via weighing system ffPlacing into trays and cartons ffDosing with highest accuracy ffFilling process under protective gas ffCalibratable weighing technology - 100 % tare/gross weighing system - 100 % gross weighing system
7 Soups & Sauces Spices
up to 240 containers/min.
Figure shows an example: OPTIMA MFL
This is what matters ffHygienic design concept ffHighest portioning accuracy through customized dosing and weighing technology ffTool-less and quick format changes ffCalibratable tare/gross weighing system ffEfficient product compression over several stations
8 Spices Soups & Sauces
The processes for dry powdered soups, sauces & spices
Cleaning of containers Closing ffAir rinsing, evacuation, turning and sterilizing ffScrew capping, press-on, position orientation, crimping ffSealing: Inductive, ultrasonic, thermal Dosing ffAdjustable speed and torque ffVolumetric system ffClosure inspection with rejection ffGravimetric system ffClosures processing from the stack or as bulk goods ffVacuum system ffProduct-specific Weighing ff100 % tare/gross weighing system (calibratable) Filling ffShut-off weigher ffCareful filling of product with cup dosing system or auger dosing machines Handling ffHigh filling accuracy ffEasy to clean ffProgrammed topping up ffSimple and quick format changes ffDust-free filling process ffCentral controls of the technical ffVibrating stations increase product density and output ffData interface to production control panel ffProcessing of mixed products ffTouch panel ffRevolving funnels ffIn-line gassing
9 Soups & Sauces Spices
up to 200 containers/min.
Figure shows an example: OPTIMA SHF This is what matters ffToolless and quick format changes ffCIP / SIP fully automatic cleaning ffChunky ingredients in liquid ffInductive without pressure vessel ffMulti-component filling
10 Spices Soups & Sauces
The processes for liquids and pasty ffSauces & spreads (sweet and savory) ffSoups & spices
Cleaning of containers Closing ffSterilizing and air rinsing ffScrew capping, pressing-on, position orientation ffSealing: Inductive, ultrasonic, thermal Dosing ffAdjustable speed and torque ffCoriolis mass flow meters (MDM) ffClosure inspection with rejection ffMagnetic-inductive flow meters (IDF) ffPiston pump Further processes ffGravimetric system ffCIP / SIP ffVolumetric system ffFilling module completely changeable - Quick change of product Filling - Avoidance of cross contamination ffLow-germ under laminar flow ffLow-germ processes under laminar flow ffHot filling, double-jacket execution ffExplosion-protected machine execution possible ffWith chunky parts ffData exchange with customer´s master system ffHigh filling accuracy ffMulti-component filling
11 Concentrates
up to 350 containers/min.
Figure shows an example: OPTIMA OF-OV
This is what matters ffTurn-key lines ffProcessing of non-freestanding containers ffCIP / SIP fully automatic cleaning ffLow-germ filling ffShort format changeover times due to carrier systems ffMinimized energy consumption
12 Concentrates
The processes for liquid concentrates
Cleaning of containers Further processes ffSterilizing and air rinsing ffCIP / SIP ffContainer feeding and/or sorting Dosing ffFilling module completely changeable ffCoriolis mass flow meters (MDM) - Quick change of product ffMagnetic-inductive flow meters (IDF) - Avoidance of cross contamination ffGravimetric system ffLow-germ processes under laminar flow ffVolumetric system ffExplosion-protected machine execution possible ffData exchange with customer´s master system Filling ff100 % weighing controll ffLow-germ under laminar flow ffContainer coding ffHot filling, double wall model ffPlacing into trays ffEnd of Line solutions Closing ffScrew capping, press-on, position orientation ffSealing: Inductive, ultrasonic, thermal ffAdjustable speed and torque ffInspection stations with rejection ffEasy format change
13 Single Serve – capsules and pods
up to 1.500 packs/min.
Figure shows an example: OPTIMA CFL
This is what matters ffModular system ffIntegrated controls / components ffOnly one operator panel for all functional modules ffFunctional modules can be moved on a patented track system ffMulti-lane and intermittently working model ffServo-driven dosing technology ffIndividual lanes can be switched off ffIntegrated weighing technology
14 Single Serve – capsules and pods
Portion packs – quickly produced and with high pressure
Since their introduction, portion packs for coffee, tea and other packaging can be taken into account individually by the modular food items are ever more in demand. Optima offers filling and pa- construction. ckaging machines specially designed for the rational and flexible The quality of the product has first priority. With the integrated manufacture of small packaging sizes. combination of dosing and weighing technology, high output ra- The special features of the various coffee types and their typical tes with the highest level of filling precision can be achieved.
Capsules Pods
Processes: Processes: ffContainer magazine and sorting ffBottom paper uncoiling ffDe-stacker and Pick-and-Place modules ffPre-forming the pad ffAuger dosing device ffDosing and filling ffPiezo-electric filling chute ffTurning the product several times ffDrum doser ffCompressing ffMultihead weigher ffCover paper uncoiling ffProduct optimization, gas flushing ffPod sealing ffWelding and sealing technology for metal, ffPunching finished pad plastic or nonwovens ffPeeling off and reducing rest paper ffClosure application under vacuum or with overpressure ffWeight control and regulation ffClosing systems, e.g. screw caps, press-on caps, ffCounting and stacking device seal caps and drag-off caps ffPlacing the pads in cassettes ffAssembly module ffCassette transport to the packing machine ffPrinting and coding systems ffInspection systems ffFully automatic sample presentation ffCartoning machines, case packers or product transfer Secondary packaging for capsules and pads
Module: Bag forming, filling, and sealing machine Processes ffFor packaging a number of stacked pads into bags of different execution. ffGassing of filled magazines ffCorner sealing ffForming of the tubular bag (VFFS) ffInserting the product stack into the bag ffGassing the product stack and the bag ffFlat bag bottoms ffSealing the bag ffPrinting ffRe-closing ffFinal check weigher
Module: Four-side seal pouch device Processes ffCapsules and pads are individually packaged with the single pouch module. In this way they are aroma protected and can be stored for a longer period without any loss ffPackaging in tubular bag of quality. ffIntegrated in the smallest space ffFoil feeding from the reel ffProcessing as half tube ffNitrogen gassing for product protection with lowest residual oxygen content ffCoding with production date and best-before date
Cartoners and case packers Processes ffIn order to present the portion packs as attractively as possible at the Point of Sale, we offer ideally suited folding boxes with an insertion or glued closure. Optima carto- ffSemi-automatic with manual work ners can be integrated directly in the process after the production, filling and closing stations to fully automatic machine. ffWorking modus intermittent or continuous ffInsertion station for packs ffCoding ffBarcode check ffProcessing in-liners, inserts or booklets
16 The SoftCan®Maker Machine solution for foil cans
Foil is made into a can
The machine solution for foil cans opens a whole new and flexible granulates and can also be packaged with use of protective gas. packaging world which unites quality with convenience. Based on the patented Cyclero® concept by Huhtamaki, Optima presents its Successful projects for the packaging of coffee pads confirm the SoftCan®Maker for this innovative type of packaging from the reel. benefits of low material consumption and warehousing costs with The machine can be flexibly combined with various dosing sys- the same security of processing and high output rates. tems. Cyclero® is suitable for chunky products or also powders and
Processes ffSides and bottom manufacture from the reel ffProcessing of a pressure control valve ffFilling the can with chunky or powder products ffFilling process under protective gas ffClosure: One-time closure by means of a peel-off foil or reclosure by means of a snap lid ffCalibratable gross weight control ffPlacing the can into a carrier or tray / carton
Figure shows an example, other can forms are possible.
This is what matters ffSimple opening and reclosing with the “easy peel off” method ffEasy to dispose of, flat and thus extremely environment-friendly ffHeight of the foil can is easily changed in only a few minutes ffFoil material transparent or with viewing window ffSignificantly lower costs compared with hard cans and glasses with respect to material, manufacture, warehousing and transport ffProduction of 15,000 cans from one reel, thus minimizing packaging material storage
17 Functional Closures Closures with additional function(s)
1 – 100 ml 50 – 240 containers/min.
Figure shows an example: OPTIMA CFL
This is what matters
ffModular machine construction enables flexible adjustment to the extensive variety of product requirements
ffOngoing automatic process ffEach process step is fully monitored ffSimple to operate ffExcellent access ffPilot lines, sample production ffLeakage test to check if the closure provides optimum protection for the product ffSemi and fully automatic machines
18 Functional Closures Closures with additional function(s)
The processes With modularly designed filling and assembly machines Optima for closures with additional function(s) Consumer provides solutions for closures with additional functio- nalities. Several machine functions can be integrated: Dosing sys- Cleaning of containers tems for contents, sorting and assembly of various components ffSterilizing and blowing-out and in addition control functions for the leak tightness of the clo- sure. Particularly important for the closure´s reliability is the accu- Dosing racy of the manufacturing process. ffCoriolis mass flow meters (MDM) ffMagnetic-inductive flow meters (IDF) This is how it works: ffVolumetric systems With activation of the Functional Closure - also called Ingredient ffProduct-specific systems Release or Dispensing Closure - liquid or dry contents automati- cally gets released into the container. Filling ffLow-germ Functional Closures are applicable for Ready-to-Drink bever- ffDust-free ages with vitamins, aromas or active ingredients to achieve a ffLiquids longer shelf-life – or simply as a new drink experience. ffPowders ffGranulates Further applications are possible for cosmetics, chemical products or OTC. Closing / Assembling ffMaterials processing from the stack or as bulk goods ffScrewing, pressing-on, position orientation ffLid sealing from the stack or roll ffAdjustable speed and torque ffSealing: inductive, ultrasonic, thermal
Further processes ffSorting systems ffContainer coding ffSeal integrity check ffControl stations with reject
19 Service Lifecycle
Service = Security
With the acquisition of an Optima machine all the benefits of a and line automation, sorting modules and conveying systems are long-term partnership are united. For example, regular mainte- available. nance by the experts of our globally available service network minimizes the risk of machine downtime. Optima emergency ser- Service begins when the machines are taken into operation. Indi- vice is available to customers around the clock in person, via tele- vidual training concepts lead to confident handling of the user service and online. friendly technology. A further aspect is that it is not always neces- Perfect service needs an extensive spare parts warehouse. Our sary to invest in new machine systems. Innovative machine up- proven logistics system guarantees that the replacement parts grades and individual conversion packages from Optima bring reach you in the shortest possible time. Original replacement your machines up to the latest state of technology. parts are of course in Optima quality. Consulting, development and integration of various systems to We also offer you an extensive selection of format parts ensure faultless filling and packaging processes e.g. SCADA sys- that enable you to respond flexibly to market changes. In parti- tems, line monitoring, track & trace solutions or optical ins- cular, components and modules such as manipulators, robots pection systems all belong to our daily business.
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20 Your contact partner We are at your service
Our Service Team is at your We can also be contacted on our We can be contacted as follows: disposal! Service-Hotline 24 hours a day: + 49 7333 808-133 Phone: +49 791 94606-0 Our hours of business: Fax: +49 791 94606-3019 Monday – Friday Contact our worldwide subsidiaries 7:00 am – 5:00 pm (CET) and service support centers. Phone: +49 791 506-0 Fax: +49 791 506-9000
E-mail: [email protected] [email protected]
21 An overview of OPTIMA consumer
Packaging machines for your chemical products
ffPesticides and fertilizers
- dry & liquid Excellence in Packaging Verpackungsmaschinen für Ihre Chemieprodukte ffWashing and cleaning agents - dry & liquid ffRefined products
Member of 10482655/1/DE
Packaging machines for OPTIMA - Excellence in Packaging your cosmetic products ffMilestones ffBody care ffGlobally active, close to the customer ffHair care ffService global Verpackungsmaschinen für Ihre Kosmetikproduktion ffDecorative cosmetics ffNonwovens ffPerfume ffConsumer ffPharma ffLife science
Member of
Service worldwide – A Comprehensive Service Program
ffStart up f Service weltweit fProduce Das lückenlose Serviceprogramm ffMaximizing availability ffOptimize ffDevelop further
Member of
OPTIMA SD1 Schneckendosierer für pulvrige oder körnige Produkte Semi-automatic machines OPTIMA SD2 best Servogesteuerter Schneckendosierer mit integrierter Abschaltwaage für pulvrige oder körnige Produkte ffAuger dosing feeders Eigenschaften
f Reproduzierbares Abfüllergebnis durch Parameterverwaltung f Optimaler Zugang durch schwenkbare Anordnung f Schnelle Produktumstellung f Stufenlos einstellbare Rührerdrehzahl ffFilling and weighing machines f Touch-Screen mit grafischer Anzeige f Auf Füllgut abgestimmte Verschließsysteme f Hochgenaue Dosierschnecken (Vollmaterial) Seitenansicht f Geschlossenes System Vorderansicht f Antrieb durch verschleißfreien Servomotor ffLiquid filling f Produktberührende Metallteile aus Edelstahl bzw. lebensmittelechten Kunststoff Absperrsystemf Sehr geringer Produktverlust durch kontinuierliche Touch-Screen UnterschiedlicheSelbstoptimierung Absperrsysteme wie z.B. Das Touch-Screen mit grafischer Oberflä- Stift-/Schieberverschluss oder Spinner che erhöht die Produktionssicherheit und Plate sind speziell auf die zu dosierenden sorgt für eine schnelle Produktumstellung. ffClosers Produkte abgestimmt. Sie erhöhen die Alle Parameter wie z.B. Drehzahl, Absperr- Genauigkeit und sorgen außerdem für zeiten und Rühreinstellung werden unter Sauberkeit im Umfeld der Dosierung. dem Produktnamen bzw. der Artikelnum- mer hinterlegt.
Dosierschnecken 30 kg Wägetechnik Die hochgenauenDosierbereich Schnecken bisund zu Der Schneckendosierer kann optional mit Buchsen aus Edelstahl sind aus dem Vol- unserer bewährten Wägetechnik kombi- len gefertigt. niert werden. Sie folgt dem Kraftkompen- sationsverfahren und erhöht die Präzision.
Technische Daten
OPTIMA SD1 Dosierbereich 100 mg – 200 g 4 – 30 mm mit unterschiedlichen Schneckendurchmesser Längen und Steigungen Gewicht ca. 250 kg Member of
OPTIMA consumer GmbH | Geschwister-Scholl-Str. 89 | 74523 Schwäbisch Hall | Germany
Tel.: +49 791 94606-0 | Fax: +49 791 94606-3019 | [email protected] | www.optima-consumer.com 10035424/2/DE Wir arbeiten ständig an der Weiterentwicklung unserer hochwertigen Maschinen. Texte, Abbildungen und Zahlenangaben in diesem Prospekt sind daher unverbindlich und exemplarisch. We will be pleased to send you further information.
22 Addresses worldwide The security of a strong partner
OPTIMA packaging group GmbH OPTIMA Machinery Corporation OPTIMA Japan Co. Ltd. Steinbeisweg 20 1330 Contract Drive 362 Shimizu-cho 74523 Schwaebisch Hall Green Bay, WI 54304, USA Kawaramachi-dori Tel.: +49 791 506-0 Tel.: +1 920 339-2222 Nijio-agaru, Nakagyo-ku Fax: +49 791 506-9000 Fax: +1 920 339-2233 Kyoto 6040911, Japan [email protected] [email protected] Tel.: +81 75 223-1588 www.optima-ger.com www.optima-usa.com Fax: +81 75 223-1595 [email protected] OPTIMA consumer GmbH OPTIMA packaging Geschwister-Scholl-Str. 89 machines, S.A. de C.V. OPTIMA Korea Ltd. 74523 Schwaebisch Hall San Jorge 198 1107 HyunDai Topics Tel.: +49 791 94606-0 Col. Pedregal Santa Úrsula 44-3 Bangi-dong, Songpa-gu, Fax: +49 791 94606-3019 Del. Coyoacán Seoul 138-827, Korea [email protected] C.P. 04600 México, D.F. México Tel.: +82 2 414 7105 www.optima-consumer.com Tel.: +52 55 5421-0271 Fax: +82 2 414 7106 Fax: +52 55 5610-4452 [email protected] OPTIMA Packaging Machinery PLC [email protected] 7 Loader Close www.optima-mex.com OPTIMA Packaging Machines Kings Worthy (Shanghai) Co., Ltd. Hampshire SO23 7TF, UK OPTIMA do Brasil Máquinas No. 695 Fengmao Road Tel.: +44 1962 620898 de Embalagem Ltda. Malu Town, Jiading District Fax: +49 791 506 6500 Rua Joana Foresto Storani, 500 Shanghai 201801, China [email protected] 13280-000 Vinhedo - SP, Brazil Tel.: +86 21 6707 0888 www.optima-gb.com Tel.: +55 19 3886-9800 Fax: +86 21 6707 0889 Fax: +55 19 3886-9810 [email protected] OPTIMA packaging France S.A.R.L. [email protected] www.optima-cn.com Zone d´Activités de l´Energie www.optima-bra.com 4, rue Ampère B.P. 9 OPTIMA PACKAGING MACHINES 59559 Comines Cédex, France OPTIMA India packaging machines (M) SDN. BHD. Tel.: +33 320 6306-48 Pvt. Ltd. 5008 A 1st Floor Fax: +33 320 6306-41 No. 2, 2nd Floor, Sri Datri Nivas Jalan Lunas, Batu 2.5 [email protected] Nagawara Circle, Outer Ring Road 09000 Kulim, Kedah www.optima-fra.com Opp. Manyata Softech Park Malaysia Bengaluru – 560045 Tel.: +60 4 495 1619 AMOTEK S.r.l. a socio unico Karnataka, India [email protected] Via Piemonte 5 Tel.: +91 80-40854449 www.optima-mal.com 40069 Zola Predosa [email protected] Bologna, Italy www.optima-ind.com Tel.: +39 051 61868-11 Fax: +39 051 61868-88 [email protected] www.amotek-ita.com
23 www.optima-consumer.com More information:
10824909/2/EN We work continuously on further improving our top quality machines. Texts, illustrations and figures on these pages are intended as examples and are non-binding.