GEA Thermoformers

GEA Thermoformers

Addressing every need Encompassing fully developed, highly individual solutions, GEA's thermoformers perfectly satisfy all food sector requirements.

Addressing every need

Packaging plays a key role in ensuring that food quality is maintained throughout the supply chain, from production to the consumer's table. The thermoformers built by GEA deliver the ideal packag­ing to achieve this goal. They incorporate the latest technology, individual efficiency-enhancing ideas, and expertise accumulated during years of collaboration with clients.

Leveraging the benefits of the global GEA Group

Within the international footprint of our diverse Group, GEA packaging machines are developed in the context of systematic innovation management. Our development engineers engage in a continuous dialogue with all the other Group business units. Solutions originated in an individual segment can therefore be applied quickly and efficiently elsewhere as well. This approach allows new opportunities to be explored, in particular along the value chain in the food industry.

UniPak

GEA UniPak
GEA UniPak Thermoformer

Designed for maximum diversity, this variant produces MAP and vacuum packaging, as well as VarioSkin and steam evacuation options. The application range spans sliced cheese and sausage, piece goods, pastries and vegetarian products. Good pack forming, easy opening features and excellent reclosing, depending on the application and materi­al, are ensured as a matter of course. This machine is capable of handling medium to high capacities.

ShrinkPak

GEA ShrinkPak
GEA ShrinkPak Thermoformer

The GEA ShrinkPak is a thermoformer for shrink film that is equipped to overcome every packaging challenge, from large shipping units to small consumer packs. Thanks to the vacuum process, followed by shrinking in a water bath/spray tunnel, the film is wrapped skin-tight around the product without creasing. Contour cutting presents the final package with only a minimal visible sealing seam.

 

Expertise with powerful roots

Thermoforming these days belongs to the GEA Food Processing & Packaging unit. This business segment is founded on decades of tradition with its origins in the fusion of several small and medium-sized processing and packaging machine companies. From this tradition - alongside continuously advanc­ing technical expertise - comes one central insight. In today's world, a good personal relationship with our customers is the foundation of long-term success.

First-class in every respect

The quality of a packaging solution is determined by numerous factors. In the key functional areas, GEA thermoformers incorporate cutting-edge technology. 

GEA Food delivers a wide range of applications like ShrinkPak, SkinPak, UniPak and TopPak for a wide spread of markets like meat, seafood, confectionery and bread as well as non food solutions.

SkinPak

GEA SkinPak
GEA SkinPak Thermoformer

This application combines outstanding product presentation with a perfect seal in a package that is easy to open, highly practical and appealing to the eye. Thanks to top film preheating, the GEA PowerPak thermoformer practically rules out creases when placing the film over the product and tray. This process avoids weight losses and effectively enhances the product's appearance. 

TopPak

GEA TopPak
GEA TopPak Thermoformer

By way of a second forming station for the top film, the GEA PowerPak produces a three-dimensional, reclosable TopForm pack. It is an ideal, attractive and individual package with an inline formed lid for sliced meat and sausage, sliced cheese, gourmet salads and snacks. 

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GEA PowerPak

The GEA PowerPak is equipped to run all commercially available web combinations for thermoforming operations, incl. speciality materials such as Aluminum foil. The maximum index of 800 mm can be utilized with all webs, heating and forming system combinations! With a choice of heating and forming systems, various cross cutting and longitudinal cutting devices and an optional machine extension for a top and bottom web labeler, the GEA PowerPak lends itself to the production of widely used vacuum and MAP pack styles. The modular frame adapts to changing requirements in future: Functional modules can be added or taken off on site.

GEA PowerPak

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Working principle 

A powerful transport chain is securely gripping the bottom web at the infeed drum. A precision servo motor indexes the web through the machine process. The index length is programmable on the HMI and stored as recipe parameter. The loading area is accessible from both sides for multiple operators. Powerful GEA Membrane seal system for reliable seals and constant peel forces. Knee lever punches for semi rigid bottom web, with central adjustment of cutting forces. Optional Strip punches for smoothly rounded pack corners, or radiused pack sides (All cross punches alternatively with servo drive). Guillotine cross cut knives for flexible bottom web,optional tear notch cutting. Choice of longitudinal cutting systems with optional strip cutting for superior pack quality. For increased running time with long indexes, jumbo unwinds for top and bottom web can be utilized.

  • Standard servo motor for transport chain indexing
  • Optional servo drives for lifting systems and cross punches 
  • Proven, long lasting high precision cutting systems, easily adjustable 

Performance

The robust machine frame, latest control and drive technology are the basis for secure production. The GEA membrane seal head ensures tight and even seals, with only a minimum of maintenance required. A choice of vacuum pumps is available, with external placement of larger pumps. Built to perform in 24/7 production environments, with minimum maintenance demands.

  • Parameter stored in individual recipes, for constant batch run quality
  • Robust machine frame
  • Reliable components from established suppliers
  • Seamless integration with GEA End-of-Line components

Output quality

Choice of Heating and Forming systems to run a variety of bottom web types. Optional OptiForm plugs for even web distribution in deeper trays. GEA Membrane seal system guarantees high seal forces with even distribution over the whole sealing surface, for consistent results with peelable webs and reliably tight seals. Optional lifting die tops to prevent heat impact on sensitive films or products during machine stops.

  • GEA Membrane seal system for tight seals and even peel opening
  • Various peel corner designs for easy opening
  • Choice of heating and forming systems for stable, well defined pack forming
  • Choice of cutting systems for smoothly rounded pack corners
  • Optional product detection systems with faulty pack eject on optional PowerGuide systems

Flexibility

The GEA PowerPak utilizes a modular machine frame concept. The machine can be adapted to changing requirements in future. Loading area extension for integration into packaging lines with automated loading; - Labeling extension for installation of top and bottom web labeler; - Choice of Cutting systems to handle a huge variety of film types; - TopForm option. A wide range of different quick die change options allow for an individual setup to minimize tool change down times in different production setups

  • Modular machine frame
  • Optional print mark detection with top web brake; Unique function for fast adaptation to changing print mark distances
  • Choice of air, vacuum or MAP packs or unique cardboard/plastic combinations
 

Minimized scheduled maintenance demands

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Reliability

The GEA PowerPak is built to endure 24/7 production environments with minimized scheduled maintenance demands. Deliberately oversized structural components in the machine frame and lifting systems ensure years of operational life under huge mechanical load conditions. Main components from leading specialized suppliers are used throughout the machine, ensuring the usage state-of-the-art technology in performance-critical areas.

Hygiene

Open, extremely robust, stainless steel frame with spacers for internal tubing and wires. Soft key selector switch for cleaning mode ("tools up") to prevent water damage and condensation water built-up. Sloped surfaces prevent accumulation of water. Hinged side sheets remain on the machine during cleaning and sanitation, while still allowing easy access to all interior structures for thorough cleaning. Special maintenance- free bearings in the lifting system run without needing grease on the shafts. Pneumatics and electrics/ electronics separated in two different cabinets.

  • Sanitary open frame design
  • No greasing of bearings required
  • Cleaning mode for tooling and transport chains
  • US Dairy 3A certification
  • Sloped surfaces and hinged side sheets

Safety

The GEA PowerPak meets all current national and international standards for safe machine operation and is compliant with EU Machine directive 2006/42/EC.

  • CE labeled
  • BG approved (independent German certifying body)
  • State-of-the-art RFID- based technology for safety guarding
  • Optional: UL approved

Controls

GEA Controls are ideally suited to operate the machine both as stand-alone, or fully integrated into the company's network. On onboard Ethernet interface is standard! The large 10" HMI Color Touch Panel offer multiple language choices. Operators find the symbol based main control surface very easy to work with. Optional RFID tags allow for an access control to quality relevant machine settings. Troubleshooting and error evaluation via remote access and VNC viewer. Customized HMI surface: Individual selection of most frequently used icons on front page.

  • Proven, non- proprietary PLC with IPC functionality; network ready
  • Unlimited recipe storage
  • Recipe backup on USB sticks
  • PLC program backup on CF card; Remote access for trouble shooting
  • Intuitive, symbol- based HMI surface; Optional RFID tag controlled individual access levels

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GEA DeltaPak

The GEA DeltaPak thermoformer is adapted to your vacuum and MAP applications. The conversion to another pack size is simple and achieved in a few easy steps. To tailor fit our solution to your requirements the GEA DeltaPak can easily be extended with carefully selected downstream components. The wealth of experience gained by our customers in decades of operating our machines has been put to good use here.

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GEA DeltaPak

Working principle

A powerful transport chain is securely gripping the bottom web at the infeed drum. A precision servo motor indexes the web through the machine process. The loading area is accessible from both sides for multiple operators. Powerful GEA Membrane seal system for reliable seals and constant peel forces. Knee lever punches for semi rigid bottom web, with central adjustment of cutting forces. Guillotine cross cut knives for flexible bottom web,optional tear notch cutting. Choice of longitudinal cutting systems. 

  • Strongest chain grippers in the market to hold all types of film
  • Optional labelers and / or direct print
  • High performance valves  

Performance

All our machines are ruggedly built and thus safeguard the consistent quality of the finished packages 24/7, for years to come. Our machines have proved their worth, especially in harsh environments, such as those in the fish processing industry. We place particular importance on the generous use of high-quality materials, high-performance drive technology from premium manufacturers and continuous implementation of high quality German valves. The GEA membrane seal head ensures tight and even seals, with only a minimum of maintenance required. 

  • Robust machine frame
  • Up to 99% technical availability
  • High quality German components
  • GEA membrane seal head ensures tight and even seals
  • 24/7 Helpdesk 

Output quality

The GEA DeltaPak ensures that all packages are neatly sealed with the greatest possible reliability. The process parameters measured, such as heating temperature, compressed air supply, cooling water throughput, vacuum values, process times etc. are constantly monitored and logged. 

  • Permanent monitoring of critical process steps
  • Selected variety of easy opening features
  • Heating and forming system for stable, well-defined pack forming
  • Cutting system for smoothly rounded pack corners 
 
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Hygiene is the key issue in packaging

Reliability

A whole series of design solutions contribute to meeting the objective of perfect packaging. The special membrane sealing system - the centerpiece of our machine - we achieve a particularly high and even contact pressure for sealing the upper with the lower film. The GEA DeltaPak range is built to endure 24/7 production environments with minimized scheduled maintenance demands. Typically, our individual machines are 98-99% available (machine technical availability in accordance with DIN 8743). Components from premium suppliers are used throughout the machine, ensuring the usage state-of-the-art technology in performance critical areas. 

Hygiene

Hygiene is the key issue in packaging. Our responses to these challenges are multifaceted - technically as well as organizationally: All machine surfaces in the loading area are entirely smooth and therefore especially easy to clean. The side panels are easy to hinge for full cleaning access of inside components. Soft key selector switch for cleaning mode ("tools up") to prevent water damage and condensation water built-up. Our defined cleaning processes and cleaning agents are certified by independent hygiene institutes. You receive cleaning training videos as part of our machine documentation. Our machines are certifiable according to 3A Dairy; we also fully comply with DIN EN 1672-2 and NSF/ANSI 14159-1. 

  • Sanitary open frame design
  • No greasing of bearings required
  • Cleaning mode for tooling and transport chains
  • Cleaning mode for tooling and transport chains
  • Sloped surfaces and hinged side sheets 

Controls

Intuitive operation using pictograms, and easy change of language for the user interface. Faults are displayed in easily comprehensible plain text in the selected language The personalized, configurable user interface simplifies each operator's individual access A graded authorisation system with reliable access control safeguards operation. The relevant process data for processing a product with its packaging are saved as a recipe in the machine controller. These recipes can optionally be saved on a USB stick for data backup. The machine's operating system can also be stored on a standard Compact Flash (CF) card. This way the original machine status can be completely restored after replacing the control hardware. On replacement of process peripherals (e.g. a drive unit controller), the required control parameters from the controller can be transferred to the periphery controller (Plug and play). GEA Controls are ideally suited to operate the machine both as stand-alone, or fully integrated into the company's network. On on-board Ethernet interface is standard! Optional RFID tags allow for an access control to quality relevant machine settings. Troubleshooting and error evaluation via remote access and VNC viewer. Customized HMI surface: Individual selection of most frequently used icons on front page. 

  • Proven, non- proprietary PLC with IPC functionality; network ready
  • Unlimited recipe storage
  • Recipe backup
  • PLC program backup on CF card; Remote access for trouble shooting
  • Intuitive, symbol- based HMI surface; Optional RFID tag controlled individual access levels

Contact

How can we help you?