Process-reliable implementation of new packaging materials
New packaging materials can have a significant impact on packaging processes. KOCH develops machine technologies designed for the reliable processing of a wide range of material concepts and supports requirements related to material usage, recyclability, and PPWR compliance.
From the requirement to an integrated packaging concept
Sustainable packaging is more than just a new material. What matters is that design, material, and machine fit together. Otherwise, waste, downtime, and costs increase.
KOCH brings together packaging concepts and machine technology. We test materials and process parameters, optimize sealing and handling performance, and integrate the right technologies to support an efficient and reliable implementation.
Reduced film consumption and perfectly sealed blisters: We achieve this goal by sealing using ultrasonic welding. This process allows for significantly narrower sealing edges. In addition, the forming and sealing materials can be identical, so the packaging can be fed directly into the recycling process without separating the components.
Process and advantages
With the patented Smart Heating process, a part-specific heater delivers the heating energy with exact dosage. This allows the material thickness at every position of the packaging to be perfectly controlled – for an overall reduced film thickness while simultaneously optimizing blister quality.
Process and Advantages
The software-based forming process enables a faster build-up of pressure in the mold cavity, resulting in optimized material distribution and reduced film consumption. This allows the use of thinner films, while the blisters remain stable and of the highest quality. Thanks to the increased pressure, the forming process is also faster and more productive. Temperature-controlled tools ensure good blisters from the very first cycle, and an air shower in the forming station provides optimally tempered film even when the machine stops. The process can be restarted without material loss.
Process and Advantages
Intelligent cutting methods ensure significant material savings, especially for small products. Depending on the packaging shape, we select the appropriate method and, by optimally utilizing the machine format, ensure that very little or even no film waste is generated in the process.
Methods and Advantages
Higher packaging machine productivity can support more efficient use of energy and materials per package. Throughout the entire packaging process, a variety of technical features are used, which together enable overall higher machine and line availability.
Processes and Advantages
Turnkey: The Complete System in Focus
Turnkey means packaging solutions are not viewed in isolation, but planned and implemented as an integrated system encompassing materials, packaging design, process chain, and technology.
Sustainability & Responsibility
With KOCH, you reduce material usage by up to 30%, use monomaterials, and achieve your ESG goals – without compromising on protection or appearance.
The PPWR increases pressure on recyclability, material efficiency, and traceability. KOCH supports you with machine technologies and process concepts that enable the reliable processing of new materials and packaging formats. This is demonstrated by our approaches to material and energy reduction, such as Smart Heating, Smart Forming, and Clever Cutting.
Clever Cutting complements this through intelligent cutting concepts that significantly reduce or even completely eliminate film waste depending on the packaging design. This includes, for example, longitudinal and transverse cutting without residual scrap or optimized, offset tool arrangements with reduced cutting bridges.
With the Smart Heating process, heating energy is precisely dosed and controlled according to the specific blister shape. This reduces the energy required to heat the film and allows precise control of material distribution. In combination with the use of pre-forming plugs, overall film thickness can be reduced to a minimum while maintaining optimized blister quality.
Smart Forming ensures optimized material distribution and reduced film consumption through faster pressure build-up in the forming cavity. This makes it possible to use thinner films while maintaining stable, high-quality blisters. In addition, temperature-controlled tools and an air shower in the forming station support efficient restart without material loss.
The combination of these technologies enables particularly challenging blister designs with high dimensional stability and low production costs.