GEA PowerPak

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.

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

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.

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.

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.

GEA PowerPak Mid-Size was developed to meet efficiently any customer's demands for packaging fresh meat, pieces of food and sliced products with medium production outputs. As a compact and versatile configuration that can be also 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 Mid-Size is ideal for customized solutions and offers the benefits of GEA thermoforming packaging machines at the disposal of medium-sized production capacities companies and facilities. It can be equipped with the innovative GEA PowerJet or GEA PowerHeat to meet sustainability targets: use of recyclable mono-plastics or paper-based materials

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.

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.

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 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.

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.

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 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 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