Rotary Packaging Machines
Carousel filling & sealing machines for pre-made bags
Our rotary filling machines are the ideal solution for the automatic packaging of premade pouches when high output volumes are required. The filling and sealing machines combine high process reliability, robust mechanics, and a hygienic design. Thanks to the precise cam control, high-quality components, and fully mechanical synchronization, the machines achieve consistent sealing quality, high cycle rates, and a long service life.
In addition to Simplex machines, Duplex systems are available for maximum speed. The carousel packaging machines feature 8–10 stations and allow for individual adaptation to the product, application, and production environment through numerous optional functions.
- Ideal for granules & larger, chunky products (piece products).
- Toolless format changeover to new bag formats
- Suitable for flat pouches and stand-up bags like doypacks and blockbottom bags
- Suitable for all heat-sealable film materials
- Carousel system with 8 or 10 stations
- Designed as a simplex & duplex machine for up to 90 bags/minute
- Can be customized individually
- Integrated Take-Away Conveyor for finished packs
- Fully mechanical drive with precision cam system and only one main motor: perfect synchronisation without collisions
- Hygienic design with mirror-polished stainless steel surfaces
- Optional automatic central oiling system for minimal maintenance
Model overview
High-speed DUPLEX machine with 8 stations
Compatible bag dimensions:
- Width: 60 mm – 160 mm
- Length: 100 mm – 300 mm
Speed*: up to 90 bags/minute (equivalent to 45 cycles/minute)
*The speed depends on various external factors, such as the characteristics of the bags (bag type/size and film material), the product and the quantity of product per package, as well as the dosing system used, the product transfer, and the respective configuration of the packaging machine.
High-speed SIMPLEX machine with 10 stations
Compatible bag dimensions:
- Width: 60 mm – 160 mm
- Length: 100 mm – 300 mm
Speed:
- Reference*: 40–60 bags/minute
- Max. mechanical speed: approx. 80 cycles/minute
*The speed depends on various external factors, such as the characteristics of the bags (bag type/size and film material), the product and the quantity of product per package, as well as the dosing system used, the product transfer, and the respective configuration of the packaging machine.
Highspeed-Simplex-Maschine mit 10 Stationen
Compatible bag dimensions:
- Width: 80 mm – 230 mm
- Length: 100 mm – 350 mm
Speed:
- Reference*: 40–60 bags/minute
- Max. mechanical speed: approx. 80 cycles/minute
*The speed depends on various external factors, such as the characteristics of the bags (bag type/size and film material), the product and the quantity of product per package, as well as the dosing system used, the product transfer, and the respective configuration of the packaging machine.
SIMPLEX machine with 8 stations
Compatible bag dimensions:
- Width: 80 mm – 230 mm
- Length: 100 mm – 350 mm
Speed:
- Reference*: 25–45 bags/minute
- Max. mechanical speed: approx. 70 cycles/minute
*The speed depends on various external factors, such as the characteristics of the bags (bag type/size and film material), the product and the quantity of product per package, as well as the dosing system used, the product transfer, and the respective configuration of the packaging machine.
SIMPLEX machine with 8 stations
Compatible bag dimensions:
- Width: 130 mm — 260 mm
- Length: 100 mm – 400 mm
Speed:
- Reference*: 20–40 bags/minute
- Max. mechanical speed: approx. 60 cycles/minute
*The speed depends on various external factors, such as the characteristics of the bags (bag type/size and film material), the product and the quantity of product per package, as well as the dosing system used, the product transfer, and the respective configuration of the packaging machine.
SIMPLEX machine with 8 stations
Compatible bag dimensions:
- Width: 180 mm – 300 mm
- Length: 200 mm – 450 mm
Speed*:
- Reference: 15–35 bags/minute
- Max. mechanical speed: approx. 50 cycles/minute
*The speed depends on various external factors, such as the characteristics of the bags (bag type/size and film material), the product and the quantity of product per package, as well as the dosing system used, the product transfer, and the respective configuration of the packaging machine.
SIMPLEX machine with 8 stations
Compatible bag dimensions:
- Width: 240 mm – 380 mm
- Length: 200 mm – 450 mm
Speed*:
- Reference: 10–30 bags/minute
- Max. mechanical speed: approx. 40 cycles/minute
*The speed depends on various external factors, such as the characteristics of the bags (bag type/size and film material), the product and the quantity of product per package, as well as the dosing system used, the product transfer, and the respective configuration of the packaging machine.
Construction of an 8‑station machine
The station allocation of a 10-station carousel is as follows by default: (1) Bag removal from magazine, (2) Reserve for optional function, (3) Bag opening, (4) Filling station, (5–8) Reserve for optional functions, (9) Pre-sealing, (10) Final sealing and ejection of the finished package onto the integrated discharge conveyor belt.
1. Removing the bag from the magazine
2. Reserve station for options such as printers and zipper openers
3. Bag opener (vacuum suction device)
Optional for stand-up pouches: also available with additional pouch bottom opener (vacuum) or pouch inflation (compressed air)
4. Filling station 1 (standard)
5. Reserve station for options such as a second filling station or a material pusher
6. Reserve station for options such as tightening/straightening the bag, cleaning the bag tip, or ejecting empty packages
7. Sealing station 1 for pre-sealing
8. Sealing station 2 for final sealing with pattern, optionally with Euro hole crimping
Special options
Below you will find a list of various integrable functions. Click on the respective item to display further explanations. Please note that this is only a small selection and that further options are available. We would be happy to assist you in configuring a machine for your products and requirements.
Optionally, a horizontal bag conveyor magazine can be selected instead of the standard stack magazine, into which the bags are inserted in a fanned-out arrangement. Separation is carried out by means of driven PU round belts and rotating brush rollers.
Automatic central lubrication minimizes maintenance requirements and ensures constant lubrication of the mechanics, reducing wear and downtime and enabling a long service life.
A printing system can be integrated as an option to label the bags with the expiration date, batch number, and other production-specific information. You can choose between hot stamp printers and continuous inkjet printers, e.g., from KEYENCE or Videojet.
If you have preferences for a specific printer model or would like to use an existing model from your production, we will be happy to check the compatibility of your desired device with our packaging machine and integrate the system into your new plant if possible.
If the zippers on the bags are to be opened by machine, we integrate a mechanical zipper opener at the second station of the machine, which first pulls apart the bag flap at the top using vacuum suction cups, then lowers the zipper tool and pulls the flap apart so that the closed zipper is opened.
For heavy package weights, this optional roller conveyor integrated into the machine relieves the lateral bag grippers to enable safe handling of the bags.
The product vibrator pneumatically taps the bag from below at the filling station to distribute and compact the product more evenly, preventing excessive fill levels and product contamination between the sealing jaws.
When filling at high speeds, dividing the filling process into two steps using an additional filling station can increase performance and prevent blockages in the filling hopper. Alternatively, different products can be used with separate dosing systems at the filling stations (e.g., a chunky product and a liquid additive).
If the zippers on the prepackaged products are to be sealed, a mechanical zipper sealer is integrated into the machine. A sealed zipper reliably prevents fine-grained products from becoming lodged in the pressure seal, for example, which can mean that the package can no longer be resealed by the end consumer if the zippers are open.
Bags that could not be filled, for example due to an error during opening, are ejected from the machine before sealing by means of the optional empty bag ejection system using a separate ejection chute and can be returned to the magazine or filled manually.
Similar to the ejection of empty bags, the optional empty bag circulation function ensures that empty, unfilled packages are not sealed and are discharged via the integrated discharge conveyor belt together with the regular finished packages. However, the packages are not released from the machine via an ejection chute, but remain inside the machine and are automatically fed back into the packaging process.
In order to reduce the packaging volume and thus the transport volume, an optional bag air exhaust system can be integrated so that the bags are pressed together by two pneumatically driven exhaust sponges before sealing, thereby forcing air out of the bag.
To reduce the packaging volume or the oxygen content in the package in order to protect the product from oxidation, the optional simple vacuuming process using an air lance and vacuum pump removes most of the air from the package before the bag is sealed. Alternatively, complex vacuum chamber carousel can be used for maximum vacuuming.
Pre-punched Euro holes can lead to process errors when opening bags, especially in conjunction with closed zippers that have to be opened by machine. In this case, it is recommended that the hanging hole be made in the final step of the filling process. The optionally integrable Euro hole crimper punches a Euro hole or a hanging hole of any shape into the seal seam of the bag.
Our rotary pouch filling machines are based on 8–10 stations arranged in a circular configuration, where the respective process steps are executed sequentially.
The pouches, which are loaded into the magazine by the operator, are mechanically picked up (or fed) and transferred to the rotary mechanism. At the first station, the pouches are held by side grippers that secure (or fixate) the pouch until the last station (the One-Touch principle—without repeated gripping and releasing).
The width adjustment of the grippers for new pouch widths is performed tool-free by manually adjusting a central setting handwheel. The grippers at all stations automatically adapt the width, which significantly reduces changeover times and allows for retooling without requiring highly specialized technical expertise.
The operator-friendliness continues with the intuitive menu navigation, while a traffic light beacon indicates the respective operating status. The display, optionally available in German or English, allows for the activation and deactivation of individual functions (e.g., Zipper Opener ON / OFF), simple creation and saving of new programs, testing of individual machine functions, and a test menu for monitoring the inputs and outputs of the PLC (Programmable Logic Controller).
The machine is fully equipped with transparent safety doors and interlock mechanisms (or interlock guards) to ensure the safety of the operating personnel.
The product-contact parts as well as most components manufactured from stainless steel are executed with a mirror-polished finish for hygienic reasons, ensuring minimal product adhesion.
The rotary single-pouch machine is compatible with a wide variety of pouches, such as Doypacks (stand-up pouches) or flat pouches, as well as gusseted bottom pouches, cross-bottom pouches, or block bottom bags (excluding rectangular bag opening – no side-gusset bags).
The filling of the pouches can be done either automatically, for example via multihead weighers or counting machines, or semi-automatically (manually).
Rotary packaging machines are suitable for a wide range of products. In the field of bulk goods and granulated products they reliably process animal feed such as dog and cat treats, dry food, and chews, as well as nuts, beans, and dried fruit. Coffee, coffee beans, cocoa nibs, confectionery, snacks, chips, croutons, spices, grains, rice pellets, and muesli can also be filled efficiently and precisely.
For coarse or chunky products such as frozen vegetables, seafood, ready meals, fruit pieces, potato products, meat, and fish products, the machines also offer a high level of process reliability. Baked goods such as bread chips, as well as chemical granulates, fertilizers, and pellets in the non-food sector can also be processed without any problems.
In addition, the systems are well suited for moist or pickled products such as olives, cucumbers, kimchi, wet pet food, marinated goods, ready-made sauces and pastes, especially in combination with a suitable pump station.
For vacuum-sealable products such as smoked goods, dried specialties, or generally sensitive products that require special protection, the optional vacuum chamber extension and venting functions offer an optimal solution.
For Powders based on its linear design and the option to integrate a checkweighing station for automatic readjustment of our screw feeder, as well as the optional lift-fill function for dust reduction, we recommend our Machine Series Mini Linear.
Are you unsure whether this machine is suitable for your product and your bags? Then contact us now, we will be happy to help you.
The rotary packaging machines are controlled by a precise indexing system and a PLC (programmable logic controller), enabling exact control of every action and workstation, which ensures simple and accurate operation. The speed of the main machine is controlled by a frequency converter to adapt it to the specific material and the bag to be packaged.
The core components are supplied by a number of renowned international manufacturers:
Controls and electrical systems*
Central control is provided by the PLC and touchscreen from Siemens (Germany), which also supply the motion control module. Speed control is implemented by a frequency converter from Fuji (Japan) and the corresponding motor from Ever Gear (China). Other electrical components include circuit breakers, leakage protection, and electromagnetic contactors from Fuji (Japan), relays and phase sequence relays from Omron (Japan), and solid state relays from Fotek (China). Temperature control is handled by WINPARK (China).
Mechanics and motion*
Components from SMC (Japan), Airtac (Taiwan), and/or FESTO (Germany) are used for the pneumatic functions. A vacuum pump from Joysun (China) is integrated.
The mechanical parts are supported by a wide range of bearings: External cam bearings from IJK (Japan), internal cam bearings from THK (Japan), centering bearings from FAG (Germany), external centering bearings from Timken (USA), as well as several oil-free, self-lubricating bearings (including clamp openings for bag grippers), linear bearings, and industrial bearing bushes from Igus (Germany).
The cam material of the machine is Japanese 20CrMnTi steel (an alloy specially optimized for case hardening—carburizing and hardening) with a lifetime warranty.
Product contacting parts
All products that come into contact with food are made of stainless steel (V2A, 1.4301, AISI 304) and have a particularly smooth surface for maximum hygiene thanks to their mirror polish. Other parts comply with national standards for food safety and hygiene.
*We expressly reserve the right to make technical changes without prior notice.
The electrical power consumption, compressed air requirements, dimensions, and weight of the machine vary depending on the machine model and version. The following applies as a guideline for the GK-YD8-230 model:
- Electrical connection: 3‑phases, 400V, ca. 5 kW, 50 Hz
- Compressed air requirement: approx. 600 L/min, 6 bar, dry, uncontaminated
- Main dimensions: approx. 1800 * 1440 * 1310 mm
- Weight: approx. 2 tons
The machine documentation package includes maintenance instructions so that your own maintenance personnel can perform maintenance on the machine. However, the machines are generally low-maintenance, especially when using the optional automatic central lubrication system for the drive mechanism. Regular cleaning of the machine (dusting and removal of product residues) is, of course, a prerequisite for proper operation.
If you require maintenance carried out by us (on a regular basis, e.g. annually), we will be happy to draw up an individual maintenance plan for your machine, taking into account any work you wish your own staff to carry out.
Unfortunately, no further documents are currently available for download. Please contact us if you would like further information or a non-binding quote.
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