GEA PowerPak PLUS

GEA PowerPak PLUS thermoforming packaging machines have been developed to meet food producers’ demands for greater flexibility. The specific features lead to significantly reduced operating cost and higher productivity. GEA PowerPak PLUS sets new standards in efficiency, precision, availability and quality. Top and bottom web motorized and stabilized unwind systems, with automatic alignment, ends daily film issues. A newly redesigned sealing station offers easier access and safer handling.

Key benefits

Ensure controlled and high-quality packaging processes

• Axial positioning systems for bottom and top webs automatically compensate for layer offset and sheet running
• Minimized risk of film wrinkles or misalignment: safe film unwinding and sealing seam quality is ensured
• Innovative top film tensioning system and motorized film unwinding allows the use of extremely thin films
• Both webs perfectly positioned thanks to automatic axial adjustment of top and bottom film

Better hygiene, easy access and simple handling 

• Registration of film deviation by motorized web edge control and controlling of axial positions of both films
• Automatic film replacement positions shorten replacement times and reduce film consumption
• No mechanical brake mechanisms mean protection of dust and dirt
• Redesigned sealing station with vertically movable safety doors for easy and quick access

Reduce the costs of the packaging process and raise the production capacity

• Up to €30.000 savings on packaging materials and labor costs per year
• Up to 210 hours more production time per year
• Up to 1.200.000 packages more per year
• Over 98% uptime, monitored and proven in the field

General benefits of GEA PowerPak series are also applicable to the GEA PowerPak PLUS thermoforming packaging machines.

The unwinding systems for the top and bottom films are motorized and synchronized with the machine's advancing cycle. Working with the innovative web tensioning system, they allow controlled unwinding and a simplified and secure film path. This means optimum film tension due to extremely low and even force progression on the sealing seams.  An automatic film replacement position, and a simplified and shortened film path, cut film replacement times and film consumption when changing.

The machine runs fully automatically and has high uptime. Infeed of the bottom and top film is safe, and they fit accurately to each other. Due to constant monitoring by adjustable tolerances the positioning of the film in an axial direction is safe and flexible. The machine regulates itself, so no manual intervention is necessary. Machine downtimes are minimized. There are two-sided web reel supports on both the bottom and top web.

For better protection and easier handling, the whole GEA PowerPak PLUS sealing station is equipped with vertical sliding safety doors. The doors are hinged to rails embedded into all four sides of the frame and made of perforated stainless steel or acrylic glass for a better view inside. In the up position, the doors shield the sealing and gassing process. When moved down, all components of the station are instantly in reach.

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

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 160 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