Define the pouch construction before selecting equipment
“Pre-made pouch” covers several materially different packs. Gussets, zippers, tear notches, valves, spouts, handles and laminate stiffness all affect feeding and sealing.
| Pouch feature | Record | Equipment consequence |
|---|---|---|
| External size | Width, height and filled depth. | Magazine, grippers, opening stroke and discharge clearance. |
| Top geometry | Straight, shaped, zipper, tear notch or header. | Pickup datum, opening method and seal position. |
| Bottom | Flat, stand-up gusset or shaped base. | Support during filling and stability after discharge. |
| Laminate | Structure, thickness, stiffness and seal window. | Opening reliability and sealing parameters. |
| Print datum | Artwork position and code area. | Orientation, sensing and code placement. |
Feed one pouch, open it fully and prove that it is open
Magazine or manual load
Present pouches consistently without bending zippers, blocking pickup surfaces or mixing orientations.
Pick and separate
Remove one pouch without double-picks; manage static and laminate cling.
Transfer and grip
Hold the pouch at a repeatable datum without marking the print or obstructing the seal zone.
Open the mouth
Use vacuum, air, mechanical assistance or a combination suited to the laminate and format.
Verify opening
Prevent dosing into a closed, doubled or missing pouch; define the reject response.
A fast filler cannot compensate for inconsistent pouch separation or incomplete opening. Test production batches of pouches, including normal material variation.
Support the pouch as its shape and centre of gravity change
Flexible packs can sag, swing or pull out of the grippers as weight increases. Product delivery should be coordinated with pouch support and nozzle motion.
Nozzle entry
Confirm the opening is large enough for the nozzle and representative inclusions without touching the seal faces.
Fill profile
Use an appropriate start/stop profile to control splash, foaming and sudden pouch movement.
Bottom support
Support stand-up formats or heavy fills so grippers do not carry the complete load.
Headspace and deaeration
Define the required unfilled area and whether air displacement or settling time is needed.
Keep product out of the seal zone and control the seal window
The pouch must arrive at the sealing jaws flat, correctly tensioned and free from product, moisture, folds and trapped pieces.
- Define the top-seal width and distance from zipper, tear notch and artwork.
- Allow product settling before the pouch transitions to the seal station.
- Use drip control and, where appropriate, seal-zone protection or cleaning measures.
- Establish jaw temperature, pressure and dwell using the actual laminate specification.
- Plan cooling or compression after sealing when required by the material and speed.
- Define how seal contamination or incomplete seals are identified and rejected.
Coordinate zipper closure, top seal and variable coding
| Feature | Planning question | Evidence |
|---|---|---|
| Zipper | Must it be opened before filling and reclosed before top sealing? | Repeatable consumer opening and reclosure. |
| Top seal | What seal window does the laminate supplier specify? | Agreed peel/leak/visual result. |
| Gas or air management | Is headspace control, vacuum or gas introduction required? | Pack shape and agreed residual condition. |
| Batch/date code | Is the code applied before or after filling and where is the stable print area? | Readable code after sealing and handling. |
| Discharge | Can the warm, flexible pouch be laid down or stood up without stressing the seal? | No seal damage, scuffing or uncontrolled falls. |
Use a trial matrix, not one ideal pouch
Run pouches from more than one part of the supplied batch and include low/high fill volumes, product temperature limits and representative inclusions.
Record pouch loss by cause—no pick, double pick, failed opening, fill contamination, seal fault or discharge damage. This shows where the line actually needs improvement.