As sustainable packaging solutions grow in importance, energy-efficient technologies are increasingly coming into focus within the industry. With the Evofilm Stretchpacker, equipment manufacturer Sidel has developed a new packaging machine that bundles multipacks without a thermal shrink process. Instead of heat, the machine utilizes the mechanical properties of modern stretch films to create stable packaging units with defined tension. The solution significantly reduces both energy consumption and material usage while simultaneously shortening the required line length. At the heart of the automation is the modular “Movi-C” system from SEW-Eurodrive.

Sidel’s packaging machine reduces energy and material consumption

Traditional shrink wrappers require a thermal process in which the film is heated and then shrinks tightly around the product. This technology is proven but requires a shrink tunnel, additional line length, and energy for the heating process. Sidel’s packaging machine takes a different approach. In the stretch process, an elastic film is pre-stretched and wrapped around the product group in a controlled manner. The targeted tension ensures that a form-fitting holding force is created.

The elimination of the shrink tunnel offers several advantages: Since no heat is applied to the products, the process is particularly suitable for heat-sensitive contents. At the same time, the transparency of the stretch film is preserved, which enhances product presentation in retail settings.

• Energy consumption is reduced by more than 90 percent
• Film consumption is reduced by over 50 percent
• The machine layout becomes more compact

Sidel packaging machine for up to 80 units per minute

The Evofilm Stretchpacker integrates all relevant process steps into a compact machine structure. These include product feeding and grouping, precise film unwinding, application, and subsequent transfer to downstream stations.

The system achieves output rates of up to 80 packaging units per minute. It can be flexibly integrated into existing production lines and is suitable for a wide variety of container formats. The technology particularly demonstrates its strengths with multipacks consisting of cans as well as PET or glass bottles. Different weights and surfaces can be processed with consistent quality without thermal influences compromising product quality. Applications in the food industry as well as in household and personal care products also benefit from the precise tensioning of the film.

Highly synchronized motion control: Automation as the backbone of the packaging machine

For controlling the packaging machine, Sidel relies on the “Movi-C” automation module from SEW-Eurodrive. The platform combines control, drive technology, and application software into a seamless system. A total of ten drives work together synchronously and handle key tasks such as: This synchrony is crucial for precisely maintaining cycle times, web profiles, and film tension. Among other things, backlash-free servo drives, decentralized drive systems, and compact multi-axis systems for dynamic movements are used. The central controller coordinates web profiles, recipes, condition monitoring, and diagnostics.

• Product grouping
• Film unwinding
• Tension control
• Strapping of packaging units
• Transfer to the next station

Recipe management facilitates format changes

A central component of the stretch wrapping process is the precise control of film tension. Material- and product-specific parameters such as pre-stretch, braking torques, or friction coefficients are stored in recipes. When changing container formats, these parameters can be loaded automatically. This shortens setup times and helps reduce operator errors. At the same time, the integrated diagnostics support continuous monitoring of the process.

Packaging machine supports sustainable production

The advantages of the technology are particularly evident in terms of sustainability and operating costs. In addition to reduced energy consumption and lower material usage, operators also benefit from a more compact system layout. The elimination of thermal units reduces the amount of production space required. Furthermore, recycled film materials can be used, which supports regulatory requirements and sustainability goals.

Integration into existing production lines

Thanks to its modular architecture and standardized interfaces, Sidel’s packaging machine can be integrated into both new plant concepts and existing production lines. The solution can be combined with conveyor systems, inspection systems, labeling units, or palletizers. Retrofit projects also benefit from this, as existing shrink systems can be replaced while simultaneously reducing energy consumption and space requirements.

Packaging machine: A path toward sustainable secondary packaging

With the Evofilm Stretchpacker, Sidel is pursuing an approach that combines mechanical precision, automation, and resource efficiency. The combination of highly synchronized drive technology, recipe-controlled process management, and energy-optimized machine architecture enables stable packaging processes while reducing material and energy consumption.

For manufacturers of beverages, food, or consumer goods, this technology offers an alternative to traditional shrink packaging and supports the transition to more sustainable packaging concepts.

Author

Andrea Balser
Press Relations Specialist at SEW-Eurodrive