Kann ich auf einer Maschine viele Formate produzieren?

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Yes, a packaging machine can produce different formats. However, the level of flexibility depends on how different the required formats are and how the machine has been designed.

When evaluating a sachet or stick pack machine, it is therefore important to distinguish between parameters that can be adjusted directly from the HMI and format changes that require dedicated mechanical parts or modifications to specific machine groups.

This distinction is essential when manufacturers need to manage multiple SKUs, different doses or different package dimensions on the same production equipment.

What can usually be adjusted without changing mechanical parts?

Some format parameters can be modified relatively easily.

On Universal Pack sachet and stick pack machines, parameters such as pack length and dosing range can be adjusted through the HMI within the operating range defined for the machine.

This makes it possible to manufacture different pack sizes or doses without necessarily replacing mechanical components.

For example, when two products use the same pack width but require a different sachet or stick pack length, the adjustment can often be managed through machine settings.

The situation changes when the difference between formats becomes more significant.

When does a packaging machine require a mechanical format change?

A mechanical format change may be required when the new package differs substantially from the original configuration.

A change in sachet or stick pack width, for example, can affect the sealing and forming areas of the machine. A significant change in the required dose can also influence the dosing system and the dimensions of the components that handle the product.

These requirements should ideally be identified when the packaging machine is being designed.

Knowing the complete range of formats that a manufacturer intends to produce allows the machine configuration to be developed around both current and future production requirements.

This is particularly important for companies managing several SKUs or planning to introduce new pack sizes over the lifetime of the equipment.

Which parts of a sachet or stick pack machine are involved in a format change?

On a stand-alone vertical packaging machine, format changes can mainly affect two areas: the dosing system and the sealing system.

The extent of the change depends on the difference between the products, doses and package dimensions to be handled.

For this reason, there is no universal answer to how many formats a single packaging machine can produce.

Two formats with similar dimensions may require only limited adjustments, while formats with substantially different widths or dosing requirements can require dedicated format parts.

The most suitable configuration therefore depends on the complete format matrix required by the manufacturer.

How can a multi-format packaging machine simplify changeovers?

When frequent format changes are expected, a packaging machine can be designed specifically to provide a higher level of flexibility.

Solutions such as adjustable sealing systems and modular machine configurations can simplify the changeover process and reduce the number of operations required when moving from one format to another.

Universal Pack has developed flexible sachet and stick pack machine configurations precisely for applications where different package dimensions or product types need to be handled on the same equipment.

For sachet applications, flexible configurations can allow the sachet width to be adjusted according to production requirements.

For stick pack applications, modular solutions can be used to simplify changes in stick pack width.

The objective is not simply to increase the theoretical number of formats that can be produced, but to make the required changeovers practical for the real production environment.

What happens when the packaging machine is part of a complete line?

Format flexibility becomes more complex when the primary packaging machine is connected to secondary packaging equipment.

In a complete line, a different sachet or stick pack format can also affect the equipment located downstream of the packaging machine.

Depending on the line configuration, format parts or adjustments may be required in:

• the connecting and transfer units;
• the conveying systems;
• the counting and stacking systems;

the carton forming equipment;

and the carton closing system.

For this reason, when different primary and secondary packaging formats are required, the entire packaging line should be considered during the format analysis, rather than evaluating the sachet or stick pack machine alone.

A change in the dimensions of the primary package may also influence how the packs are transported, grouped, counted and inserted into the final carton.

Why should future formats be defined before designing the machine?

Format flexibility is most effective when it is considered from the beginning of the project.

Providing the packaging machine manufacturer with a complete overview of the expected products, doses, sachet or stick pack dimensions and secondary packaging requirements makes it possible to identify which adjustments can be managed through machine settings and which ones will require dedicated format parts.

This helps define a machine configuration that is aligned with the manufacturer’s actual production strategy.

The main information to evaluate includes the minimum and maximum pack width, pack length, required dose range, product characteristics, packaging material and, for complete lines, the different carton formats and pack counts.

Is a highly flexible machine always the best solution?

Not necessarily.

The best packaging solution is the one designed around the formats that actually need to be produced.

If production is based on one stable format with very high output requirements, a dedicated configuration may be appropriate.

When production includes several SKUs, different pack dimensions or potentially changing requirements, a more modular and flexible machine configuration can provide important operational advantages.

The important point is to define the required format range before the final machine configuration is selected.

So, how many formats can one packaging machine produce?

Potentially many, provided that the differences between those formats have been considered during the machine design.

Minor changes such as pack length or dosing adjustments may be managed through the HMI within the machine’s configured operating range.

More substantial variations, particularly in pack width or dosing requirements, may require dedicated mechanical components or a machine designed specifically for quick and modular format changeovers.

For complete packaging lines, the impact of the format change must also be evaluated on conveying, counting and cartoning equipment.

The right question is therefore not simply:

“How many formats can this packaging machine produce?”

but rather:

“Which formats do we need to produce, and how can the machine be designed to change between them efficiently?”

This is the starting point for defining a packaging system that combines production performance with long-term flexibility.

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