FormFill

&Seal
Packaging machines for
the food and dairy industries

The safe, high performance, flexible solution

for thermoforming, filling, sealing and decorating
beverage, food and dairy containers.
THE SAFE, HIGH PERFORMANCE, FLEXIBLE SOLUTION FOR
THERMOFORMING, FILLING, SEALING AND DECOR ATING
BEVER AGE, FOOD AND DAIRY CONTAINERS.

UNRIVALLED SAFETY AND VERSATILITY THE MOST VERSATILE ON THE MARKET

The form-fill-seal line merges thermoforming, This solution is suitable for all commercially
filling and labeling, all in a single solution. available resins, such as PS, PP, PET and PLA.
With an extensive machine pool installed • Multi-layer roll suitable for premium
worldwide, this solution sets the market standard products and/or aseptic products with a
in terms of: long shelf life (for instance barriered PS or
• high performance (from 6.000 to 100.000 barriered PP)
containers per hour) • Suitable for hot filling (PP)
• excellent configurability (fast changeover/ • High transparency (PET) for soft drinks
double reel, hygienic and/or aseptic • Biodegradable materials (i.e. corn, wheat,
configuration) sugar beet), suitable for deep-freezing (PLA)
• user-friendliness and easy maintenance
• an aseptic high performance solution with
low chemical consumption

2
 FFS - FORM FILL & SEA L

A BROAD RANGE OF PRODUCTS AND RESINS

An ultra-wide application range covering the food, dairy and beverage sectors

PRODUCT EXAMPLES:

Food Dairy Beverage

• Soup with chunks • Creamer (UHT milk) • Juice (clear)
• Baby food • Tvorog • Juice (with pulp)
• Ketchup • Dahi or Curd • Tea
• Margarine • Yoghurt (set) • Water (still only)
• Mayonnaise • Yoghurt (stirred)
• Fruit puree • Yoghurt with pre-mixed fruit pieces
• Dessert • Quark
• Honey • Cheese
• Tomato sauce • Milk
• Jam • Pudding
• Sauces • Chocolate (cream)
• Caramel on top/bottom • Butter
• Butter

3
Total «in-line» process

HEATING AND THERMOFORMING

(WITH BRUSHLESS SERVOMOTORS)

Max 5 minutes for mold changeovers

using trolley
Energy and cost savings (zero
downtimes, lower compressed air
consumption)
FILM UNWINDING Flexible mold shape

Reel and sensors, double reel unwinder

to aid quick changeovers
Flexibility/easy maintenance
 FFS - FORM FILL & SEA L

FILLING
Manufacturers can fill at the same time 2 products with
different characteristics thanks to the double filling unit
Outstanding hygiene (all units designed for CIP)
Just-in-time fruit injection (fruit can be dosed directly
in the machine, without using external tanks)
Mass or magnetic flowmeter, recommended
respectively for:
• syrups, milk and dairy products CUTTING
• liquid products with electrical conductivity higher (FOR SINGLE SERVE
than 20 microS/cm (water, juices) UNITS OR MULTIPACK)
Wide range of filling valves (membrane, rotative, shutter),
suitable for all product characteristics Flexible cup layout
No intermediate scrap
Material consumption savings

SEALING
Broad range of lid materials (Alu, Alu-
PET, plastic multilayer, paper multilayer
with plastic or aluminum)
Peelable or sealable lids that match
product use
Low maintenance/energy consumption
Hygienic

SUITABLE FOR PREMIUM PRODUCTS

WITH A LONG SHELF LIFE

SACMI FFS is an up-to-standard solution for

managing premium product lines, preserving
their quality and maximizing their shelf life.
In the hygienic configuration, ultra-filtered air
inside the tunnel helps preserve both container
and product from any external contamination.

SPECIFICATIONS

• The tunnel, with pressurized sterile air that

closes on the plastic film, never comes into
contact with the product, thus protecting
both container and product from the
external environment
• The lid material is sanitized using UV
lamps (optional) that kill any bacteria, thus
reducing contamination

6
 FFS - FORM FILL & SEA L

Extended Shelf Life

ESL
(EXTENDED SHELF LIFE)

ESL configuration is the step forward to maximize

the shelf life of the product, minimizing the risk
of external contamination and consequent risks
of loss of quality during the entire life-cycle of
premium product.
In this case, the machine is equipped with
closed tunnel with full-sterile pressurized air,
as far as the tank.

SPECIFICATIONS

• Both tunnel and tank are pressurized with

sterile air
• The lid material is sanitized with UV lamps
• Total hygiene is ensured by steam treatment
of filters and piping
• Sterilization of all sterilized air piping
• All air filters are steam-sterilized

7
Full aseptic
configuration
The full-aseptic configuration is the ultimate solution to eliminate, any risk of contamination by
external agents, bacteria, etc. Let’s see how it works and what are the main advantages.

PROCESS

Integral part of the packaging line contamination by conveying the vapor

• Machine pre-sterilization carried out in 2 coming from the sterilization system
different stages programmed in sequence outside the filling room via a discharge port
(water steam sterilization cycle, H2O2 • All mechanical drives inside the aseptic
sterilization cycle) tunnel are protected by a steam barrier
• H2O2 vapor exhaust system protects • End-of-production cleaning (CIP)
the packaging environment from

8
 FFS - FORM FILL & SEA L

BENEFITS

The aseptic unit consists of valves, filters, • H2O2 tanks designed for continuous
special circuits and devices and runs the sterilization by immersion of forming and
machine pre-sterilization sequences and cycles lidding materials, continuously recirculated
before production and during operation. and measured according to film width to
ensure contact with all surfaces
• Continuous production of up to 48 hours
• No contamination thanks to completely
under aseptic conditions
separated steam sterilization and
• Sterile machine conditions are
hydrogen peroxide vapor circuits
permanently controlled
• H2O2 residue is removed by mechanical
• Packaging materials (cup and lid)
squeezers, aseptic air blowers and
are continuously sterilized during the
infrared lamps
machine production cycle

9
Integrated Sleeve
Applicator (ISA)
SACMI’s patented solution for the application
of shrink sleeves, also available for multi-pack
configuration operating at output rates of up
to 30,000 applications per hour. Thanks to a
latest-generation optical recognition device,
this solution can also perform decoration of
multi-packs, which are made from a single,
specially printed material reel.
This system, which SACMI integrated into
the machine without, in any way, affecting its
efficiency, offers outstanding versatility and
gloss printing with up to 8 colors.

• Up to 10 times less steam consumption

than a traditional shrinking tunnel
• Suitable for a wide range of body shapes
• Decoration on single cups or multipacks
without format changeover

10
 FFS - FORM FILL & SEA L

In-Mold Labelling
(IML)
With in-mold labeling systems (decoration with
paper label), the roll-fed process is integrated
directly into the machine.
This transformation process allows personaliza-
tion of the container via complete fusion of the la-
bel with the container during the forming process.
This system is suitable for containers with
vertical walls, allowing:

• Less expensive style decoration

• Same shape/size for multiple brands
and products

11
 SACMI reserves the right to introduce changes without notice / 31.08.2022

W W W. S A C M I . C O M
EN