Modular thermoforming packaging machine for maximum flexibility

GEA PowerPak

If you are in search of a powerful solution for vacuum and MAP packs, the GEA PowerPak thermoforming packaging machine is the right choice. It is adaptable to cover any customer's demands for packaging food and non-food products.

PowerPak

Adaptable technology for individualized horizontal packaging

Today’s consumers and retailers demand a great range of packaged food products. To enable manufacturers to react with flexibility, GEA PowerPak thermoforming packaging machines can quickly and easily be adapted to whatever needs to be packed next in line. This reliable and durable horizontal packaging machine ensures quick, safe, and smooth processing of high-quality MAP, skin, and vacuum packs with tight seals. Whether film in feed, the package size, format or die set configuration or the sealing technique can be adapted.

Main Applications

The GEA PowerPak thermoforming packaging machine packs food products such as meat and processed meat products, cheese, fish and seafood, vegetarian or vegan products, fruits and vegetables or dairy and bakery products. All well-known package types such as MAP, skin and vacuum packs or sustainable solutions including the GEA FoodTray can be produced. More details in the specifications.

Main Applications

Key benefits

Modular construction for maximum flexibility in number and shape of packages

  • Variable heating and forming systems for different bottom web and package types 
  • Comprehensive sealing techniques and adjustable length and crosswise cutting and punching systems
  • GEA labeling and printing solutions can be integrated; works with single, multiple lane & robot loading systems
  • Optional system parts and add-ons for all package types

Efficient handling of machine and packaging process

  • Easy access allows fast change of system parts and films
  • Powerful transport chain and precision servo motors 
  • Optional servo drives for lifting, cutting or punching systems or second top/bottom web infeed and unwind systems 
  • Seamless integration of systems for loading and further processing (GEA and non-GEA)

High-quality output

  • Reliable thermoforming packaging processes thanks to high-precision tools
  • Steady tractive and cutting forces throughout the system and all optionally integrated parts
  • Strong and consistent sealing forces across complete sealing surface
  • Less consumption of packaging material and consumables 

Outstanding efficiency

  • Minimal down-times thanks to refined and trouble-free design
  • Proven longevity due to durable construction of machine frame and parts
  • Proven technical functionality, quick and easy service
  • Low maintenance and high up-times up to 99%, low total cost of ownership

More details to GEA PowerPak thermoforming packaging machines

When it comes to innovative food packaging, the GEA PowerPak series set the benchmark and achieve productivity and maximum flexibility in the number and shape of packages. These reliable and durable horizontal thermoforming packaging machines offer adaptable technology for individualized, modular constructions.

Reliable technology for safe and accurate horizontal packaging

PowerPak applications

From the web infeed and film transport systems, across the heating and forming elements, to the membrane sealing modules and the cutting and separation components – a GEA PowerPak thermoformer packaging machine is made to work. Thanks to state-of-the-art technology and the decades-long experience of engineering, each detail of the flexible horizontal packaging system functions with the utmost precision.

Custom built to suit individual needs

Remain flexible as possible by choosing the right machine tools for each step in thermoforming and packaging. Exceptional efficiency is achieved through fast changing from MAP to vacuum or skin packs. The machine modules can be modified or exchanged easily. A GEA PowerPak assembled today will always match the demands of tomorrow.

Types of packages

GEA FoodTray sustainable Food Packaging innovation

The GEA PowerPak thermoformer packaging machine can be used to create different kinds of packages such as: vacuum packs, Modified Atmosphere Packs (MAP), skin packs, shrink packs, re-closable packs such as zipper or top forming, environmentally-friendly packs such as a combination of film and fiber-based materials including the GEA FoodTray or mono-plastic material.

Types of products

The GEA PowerPak thermoformer packaging machine is perfect for the safe and reliable packaging of food products, sliced or whole pieces, such as meat and processed meat products including sausages and cold cuts, cheese or dairy products, fish and seafood, vegetarian or vegan products, fruits and vegetables as well as pastries, and other baked goods.

Safety certifications

The GEA PowerPak thermoformer packaging machine meets all current international standards for safe machine operation and hygiene regulations. It has achieved the following certifications: EU machine directive 2006/42/EC compliance, CE and BGN, UL approved (optional), and US Dairy 3A (optional).

Product specifications

Thermoforming packaging machine PowerPak 460 PowerPak 560 PowerPak 700
Machine Width 460 mm 560 mm 700 mm
Film Width 240 - 460 mm 240 -560 mm 240 - 700 mm
Max. index length 800 mm 800 mm 800 mm
Max. draw depth 190 mm 190 mm 190 mm
Max. frame length 20.000 mm 20.000 mm 20.000 mm

GEA PowerPak 420S

GEA PowerPak 420S

As an entry-level configuration, the GEA PowerPak 420S was developed to operate efficiently with small to medium production outputs. This thermoforming packaging machine integrates the reliability and proven high-quality PowerPak components in a much smaller machine to achieve a compact footprint. Meanwhile its concept is geared towards speed. This means the GEA PowerPak 420S places the benefits of GEA thermoforming packaging machines at the disposal of users that process small volumes or require additional flexibility, such as for seasonal goods or distributed packaging operations in branch outlets.

Machine Width 420 mm
Film Width 320, 360, 420 mm
Max. index length 400 mm
Max. draw depth 130 mm
Max. frame length 6.000 mm
Max. thickness flexible films 280 µm
Max. thickness rigid films 500 µm
Labeling Top web film

GEA PowerPak 420X

GEA PowerPak 420X thermoforming packaging machine

GEA PowerPak 420X was developed to meet efficiently any customer's demands for packaging food and non-food products with small to medium production outputs. As a compact and versatile configuration, this thermoformer integrates the reliability and proven high-quality PowerPak components in a machine with a smaller footprint. Meanwhile it provides the same speed and can be set up as mirror image. This makes the compact GEA PowerPak 420X ideal for customized solutions and places the benefits of GEA thermoforming packaging machines at the disposal of smaller and medium-sized production companies and facilities.

Machine Width 420 mm
Film Width 240 to 420 mm
Max. index length 600 mm
Max. draw depth 130 mm
Max. frame length 12.000 mm
Max. thickness flexible films 280 µm
Max. thickness rigid films 850 µm
Labeling Top and bottom web film

GEA PowerPak 460X

GEA PowerPak 460X thermoforming packaging machine

GEA PowerPak 460X was developed to meet efficiently any customer's demands for packaging food and non-food products with medium production outputs. As a compact and versatile configuration that can be set up as mirror image, this thermoforming packaging machine flexibly and cost-efficiently produces portion and contour packs with corresponding easy opening or resealing features. This means the compact GEA PowerPak 460X is ideal for customized solutions and offers the benefits of GEA thermoforming packaging machines at the disposal of medium-sized production companies and facilities.

Machine Width 460 mm
Film Width 430, 440, 450, 460 mm
Max. index length 650 mm
Max. draw depth 130 mm
Max. frame length 12.000 mm
Max. thickness flexible films 280 µm
Max. thickness rigid films 850 µm
Labeling Top and bottom web film

Options to the GEA PowerPak thermoforming packaging machine

Thanks to its modular design, each GEA PowerPak machine can be assembled individually to match any food producer’s demands perfectly. The machine has different kinds of product and web feeding systems, heating, forming, sealing, and cutting possibilities. It also offers various solutions for robot loading, slicing, labelling, quality control, sorting and lane converging that can be fully integrated. With these Add-Ons, you can turn your thermoformer packaging machines into a complete packaging system.

GEA OxyCheck

GEA OxyCheck MAP packaging

An in-line quality control system that checks the residual oxygen content of every single Modified Atmosphere Pack (MAP) that leaves the GEA PowerPak and PowerPak PLUS thermoformers. It is the world's first non-invasive oxygen measurement system for MAP, and the only solution currently available for in-line quality control that inspects all the packages produced. The GEA CombiPick package sorting and converging system automatically rejects packages with the wrong oxygen levels.

GEA LeakCheck

Identifies leaks after the form-fill-seal process, ensuring the shelf-life of the product. Based on a non-invasive technique, as with the GEA OxyCheck, this in-line control system checks the seal integrity of all MAP packs produced by GEA PowerPak and PowerPak PLUS thermoformers. 100% monitoring and accurate working system. Automatically rejects packages with leaks using a package sorting and converging system such as GEA CombiPick.

GEA TiroLabel PLUS

GEA TiroLabel PLUS spring loaded pins

A cross-web labeling system for perfect integration with GEA and non-GEA thermoformers. Operating and programming is simple. Extremely high operating speed. Fast and flexible conversion. GEA TiroLabel PLUS provides reliable results, even on uneven surfaces. A motor-driven positioning unit on top and bottom with spring-loaded pins enables non-pneumatic labeling of MAP, vacuum, and skin food packs with millimeter accuracy.

GEA EasyCheck

GEA EasyCheck

A 3-in-1 content inspection system to reliably detect incorrect weights and metal contaminations of the food packages after the form-fill-seal process.  GEA EasyCheck has a product rejection system integrated, which sorts out metal-contaminated packages or those with incorrect weights and products identified also by other inspection systems such as GEA OxyCheck and LeakCheck.

GEA EasyGuide & PowerGuide

GEA PowerGuide

GEA EasyGuide and the GEA PowerGuide converger family are versatile transport solutions for the out-feed of thermoforming packaging machines. They converge from 2-6 tracks to one and achieve a speed of up to 250 packages per minute. These machines are positioned after the cutting station of thermoforming packaging systems. Transport speed is synchronized with the packaging machine’s speed.

GEA CombiPick

GEA CombiPick

Combined single pack, pick-and-place and converger system for end-of-line applications on GEA PowerPak and Powerpack PLUS thermoformer configurations. Works with digital connection to quality control systems such as GEA OxyCheck and LeakCheck, that identify out of specification packs. GEA CombiPick has a pick-and-place assembly that picks up just the good packs from the belt and converges up to six lanes of MAP, vacuum, or skin packs to a single lane outfeed.

Innovative features for GEA PowerPak thermoforming packaging machines

GEA PowerJet

GEA PowerJet

GEA PowerJet is an innovative, highly efficient evacuation and gassing system without the need of side hole punches. This smart solution is based on two longitudinal nozzle bars integrated on both sides of the sealing station of the thermoforming packaging machine. It has a highly effective evacuation and gas flushing process that achieves extremely low and uniform residual oxygen content in any food package with very low operating costs. PowerJet is particularly suitable for use with paper-based and mono-materials and provides in addition to the mentioned key benefits the following features:

  • 100% guarantee that package chambers are evacuated and gas flushed 
  • 100% separation of evacuation and gas flushing channels in nozzles 
  • No risk of cross contamination 
  • Hygienic execution and easy cleaning 
  • Elimination of cutting or punching of packaging materials 
  • No dust or fines; no risk of "angel hair" (no double cutting into film during start/stop) 
  • No side hole knives required: minimized running costs 
  • Easy access and quick release of longitudinal nozzle bars 
  • Easy and fast assembly or disassembly

GEA PowerHeat Z

GEA PowerHeat Z

GEA PowerHeat Z is an innovative, energy-efficient zone heating system for controlled, targeted, uniform heat distribution in the forming stations of the thermoforming packaging machine, where the corresponding area of the heating plate is divided into six zones. It provides excellent forming performance of all food packages and increases the package quality. This smart solution meets the most important sustainability requirements, particularly through the use of mono-materials and thinner films. PowerHeat Z comes up with the following key benefits:

  • Excellent and equal forming results, especially when mono-materials are used (e.g. Mono PP, Mono PET) 
  • Allows the use of thinner films 
  • Uniform heat distribution across the entire heating plate of the thermoformer 
  • Optimized, fast process and temperature control 
  • Excellent forming performance 
  • Increases package quality 
  • Reaches operating temperature very quickly 
  • Saves energy (typical reduction of 20 – 25%) 
  • Minimal impact on the environment

GEA PowerHeat M

GEA PowerHeat M

GEA PowerHeat M is a revolutionary, energy-efficient matrix heating system for controlled, targeted, flexible heat distribution in the forming stations of the thermoforming packaging machine, where the areas of the heating plate are divided into equal sized areas in matrix form each with many regularly arranged, small heating pixels. PowerHeat M allows the running of minimal film thickness materials while maintaining the functionality of the packs. The technology provides excellent forming performance for all types of food packages and increases the package quality. This smart solution meets the most important sustainability requirements, particularly through its use of very thin films and mono-materials. GEA PowerHeat M provides the following key benefits:

  • The opportunity to create packages with complex contours 
  • Minimizes the amount of packaging material necessary 
  • Operates with mono-materials (e.g. Mono PP, Mono PET) 
  • Optimal process control and temperature accuracy 
  • Flexible heat distribution 
  • Minimized film thickness while retaining package functionalities 
  • Optimized and fast process and temperature control 
  • Excellent forming performance 
  • Increases package quality 
  • Fast heating to operating temperature 
  • Saves energy (typical reduction of 20 – 25%) 
  • Minimal impact on environment

Related products

GEA CombiPick

GEA CombiPick

GEA CombiPick is a time and space-saving package lane converging system for form-fill-seal-machines with integrated automatic rejection of defective or empty packages.

GEA EasyCheck

GEA EasyCheck

GEA EasyCheck combines metal detection, weight control and automatic rejection of food packages in a single machine. This ensures food safety and speeds up the production of MAP, vacuum or skin packs.

GEA FoodTray

GEA FoodTray

The GEA FoodTray is a sustainable, high-quality MAP food package with only a thin bottom film reinforced by a cardboard tray to allow attractive design, food safety and save up to 80% of plastic materials. The resource-saving package produced by thermoforming packaging machines is a smart solution that provides sustainability without compromising shelf life.

GEA Lane Convergers

GEA Lane Convergers

GEA EasyGuide and the GEA PowerGuide lane converger family are versatile and flexible transport solutions for the outfeed of thermoforming packaging machines that match their speed. They converge packages from 2-6 tracks to a single or dual lane.

GEA LeakCheck & OxyCheck

GEA LeakCheck & OxyCheck

GEA LeakCheck is an in-line measurement system on thermoforming packaging machines capable of checking seal and package integrity on all forms of MAP without contact. Residual oxygen content can be measured non-invasively by the quality control system GEA OxyCheck. Both guarantee the protective function and quality of food packaging.

GEA PowerPak for skin applications

GEA PowerPak for skin applications

The GEA PowerPak thermoforming packaging machine for skin applications is the powerful solution for high-quality skin packages of food products with high protrusion ensuring excellent appearance and a long shelf life. Achieve more flexibility and versatility by producing not only skin, but MAP and vacuum packs with a single thermoformer.

GEA PowerPak PLUS

GEA PowerPak PLUS

The premium GEA PowerPak PLUS thermoforming packaging machine provides maximum control over the form-fill-seal processes for better package quality, higher production capacity, simple access and easier handling for users. This robust construction ensures better hygiene and reduces operating costs with high availably and flexibility.

GEA TiroLabel PLUS

GEA TiroLabel PLUS

The high-speed GEA TiroLabel PLUS cross-web labeling system for top and bottom webs fits into any GEA and non-GEA thermoformer and ensures precise labeling with low downtimes

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