GEA powers up thermoformer with paper-based functionality amid plastic reduction demands

11 Jan 2021 --- GEA is adding a paper-based packaging dimension to its PowerPak Plus thermoforming machine. 

The new packaging option is made from a moldable paper composite consisting of more than 80 percent paper and a residual amount of plastic for features delivering barrier properties.

“The packaging market is currently in a state of flux,” explains Volker Sassmannshausen, senior product manager thermoforming packaging systems at GEA. “While consumers and food retailers are demanding reductions in plastic usage, the food industry must ensure safe packaging from beginning to end of the supply chain.”

“Not only must all hygiene and quality standards be met, but also legal requirements which call for a significant reduction in the amount of plastic used in packaging. When developing our machines, we always take our cues from what our customers need, so this was an obvious focus area for us.” 

Sassmannshausen tells PackagingInsights customer demand for paper-based solutions has increased in recent months.

“The need for these solutions is coming from the market and the regulations, [specifically] the need to first reduce the amount of plastic film used in packaging, and second the possibility to separate completely and easily both materials – plastic film and paper – and recycle them.”

The EU Plastics Strategy requires all packaging to be recyclable in an economically viable way by 2030.Paper-based MAP packs can be produced on the new PowerPak Plus (Image credit: GEA).

Heightened hygiene, readily recyclable
The GEA PowerPak Plus thermoformer lends itself to various packaging solutions, including handling protection, vacuum, MAP and shrink packaging.

Thanks to technical modifications, this machine can now also mold coated paper. A series of functions, including those dedicated to unwinding and feeding the delicate materials, and the newly developed multi-zone heating system which is paired with sophisticated sealing, ensure fresh foods are hygienically packaged.

The benefits include effective forming and sealing and easy opening and separation of the plastic film and paper through an integrated peel corner punch, enabling convenient recycling.

The multi-zone heating system warms the coated paper to the precise temperature required in the forming station, ready for molding via vacuum and compressed air.

This process produces thermoformed packs of around 20 mm in height, into which the precut slices are inserted.

A skinny top film – measuring just 30-50 μm thick – is used to close and seal each pack before the packs are separated.

Motor-driven unwinding systems
GEA highlights its thermoformer’s key advantage lies in its motor-driven unwinding systems for the top and bottom films.

Both unwinding systems are synchronized with the machine’s advancing cycle. Only minimal force is applied to the paper solution and the top film, which are unwound in a controlled and uniform manner. Also, the membrane sealing system ensures tight and even seals.Production line with GEA PowerPak Plus. Technical adjustments have made it possible for the thermoformer to form coated paper (Image credit: GEA).

“It’s great to see we can mold paper-based materials without any difficulty,” concludes Sassmannshausen.

“Our paper-composite packaging solution is already successfully used and these products are now on supermarket shelves.”

In other GEA news, the German food and beverage machinery specialist is supplying aseptic separator systems for COVID-19 vaccine and other pharmaceutical production to Chinese biopharmaceutical company Beijing Sinovac Life Sciences through an expanded partnership.

By Joshua Poole