Efficiently packaging juice in pouches poses significant challenges due to the high water and sugar content of the beverages, which can lead to splashing, stickiness, and compromised seal integrity. Addressing these issues, Waldner North America (WNA) has partnered with a global juice co-manufacturer to deploy state-of-the-art machines designed to optimize filling and sealing processes.
Matthew Boghdady, Customer Success Manager at WNA, highlights the capabilities of their machines: “Our equipment can achieve up to 480 pouches per minute, making it the fastest on the market for high-capacity premade pouches.”
Maximizing Efficiency and Reliability
The collaboration between WNA and the juice manufacturer has significantly enhanced production efficiency. Using Waldner’s advanced filling and sealing technology, the juice company now operates at an impressive 99.78% Overall Equipment Effectiveness (OEE). Matthew Gwin, Product Manager at WNA, notes, “We’ve not only helped our partner achieve peak efficiency and speed but also provided operator training and established a robust business relationship. They now serve as a reference for our technology.”
Waldner’s machines offer several pre-filling and sealing advantages. Unlike traditional methods where pouches are manually shingled on an infeed conveyor, WNA’s machines automate this process. “We can stack pouches in a magazine, saving substantial labor and time,” Gwin explains.
The “no pouch, no fill” feature, using individual lane control, further ensures efficiency. Sensors throughout the machine verify each pouch’s presence and proper opening before filling. Pouches failing to meet these criteria are automatically rejected, preventing waste and minimizing operational disruptions.
Innovative Solutions for Splash-Free Filling
Waldner’s technology addresses the challenge of juice overflow with precision. The machines are engineered to minimize splashing by either lowering the product nozzle to the pouch or raising the pouch to the nozzle, reducing the drop height and thus the velocity of the liquid.
The sealing process incorporates both heat and ultrasonic methods. While heat sealing is common and simpler, ultrasonic sealing is notable for its ability to seal through liquids and solids, even in the presence of splashes. WNA’s partnership with Hermann Ultrasonics enables real-time feedback from the ultrasonic system, ensuring only properly sealed pouches proceed.
“Our customer’s approach of using both sealing methods proved effective,” says Boghdady. “Ultrasonic sealing handled the liquid and solid challenges, creating a hermetic seal, while heat sealing provided a clean, aesthetic finish across the pouch top.”
Waldner’s advanced machinery and innovative sealing techniques are poised to set new standards in the juice packaging industry, addressing critical challenges and delivering superior efficiency and reliability.