Ensuring Food Safety: The Ultimate Guide to Liquid Packaging Machines

Liquid filling is an essential step in production lines across a wide span of industries. Food and drink manufacturers, food service distributors, pharmaceutical companies, and more all rely on automatic liquid filling machines to package products as efficiently and effectively as possible—and last for the long haul across the supply chain.

The market is expanding rapidly. According to a study by Polaris Market Research on the automatic liquid filling market, the global liquid filling machines industry revenue is expected to increase to $5.2B by 2030. Liquid packaging machines can package liquids in less time and with less labor, allowing manufacturers and businesses across industries to increase production speed and efficiency, minimize human error, and enhance product quality.

5 Factors to Consider When Choosing a Liquid Filling Machine

Before comparing technical features of the machines, it’s helpful to first determine the factors that are most important for your business. Knowing your key considerations can ensure that the liquid filling machine you invest in supports your products now and into the future.

• Product Characteristics: The characteristics of the liquids you will be packaging, especially the viscosity and acidity, will begin to dictate the filling machine you need.
• Packaging Type: The type of liquid packaging you’re intending on using and the machine’s ability to adapt to a wide range of materials, formats, and sizes is also important. You may need a machine that can handle various sizes and shapes or one that can produce multiple products on the same line.
• Output: Understanding your current volume and output requirements can help you narrow down which liquid filling machine would work best for your business. If your volume is relatively low, investing in a solution with high automation might not have a justifiable return, but if you’re in need of a higher output, automation can improve your performance.
• Compliance with Sanitation Standards: Liquid packaging machines are typically designed with complex “fluid pathways,” which require regular cleaning to maintain cleanliness standards, especially for the food and beverage industry. Machines that feature CIP (Clean-In-Place) controls or that come apart easily for quick cleaning are growing more popular.
• Technical Support and Long-term Customer Experience: Investing in high-quality packaging machinery is no small cost. When evaluating liquid packaging machines, you’ll want to make sure that the technical support and training have the quality to match.

Fres-co’s Liquid Packaging Machine Lineup

While new packaging equipment does incur upfront costs and training, there are big benefits to moving to an automatic packaging machine. New technology is making it easier than ever to automate more and more steps of the process, ultimately improving accuracy, efficiency, and output. 

This blog post outlines our full range of vertical form, fill, and seal (VFFS) machines for liquid products, the benefits of each machine, and considerations that you should factor into your decision-making process.

1. FSU800HF: Multi-phase Filling for Hot Fill Applications

The FSU800HF is a powerful, fully automatic VFFS packaging machine specifically designed for hot fill multi-phase filling with particulate and liquid. Its multi-phase filling technology allows for liquids and solids to be combined in different ratios, meaning that higher cost components can be metered and percentages of solids to liquids can be controlled.

Package size changes can be implemented at the touch of a button, eliminating the need to stock different-sized materials and offering rapid changeover. Its user-friendly PLC-based full control interface and processing system allows for smooth and easy operation.

Additional features include:

• Stainless steel construction 
• NEMA 4X machine construction with Allen Bradley PLC controls 
• Touchscreen HMI
• Filling systems built to sanitary standards
• CIP (Clean-In-Place) controls
• Multi-phase filling (solid products and liquid products filled via separate filling systems)
• Vertical seals made with heat sealing
• Production speed up to 30-35 cpm*
• Package capacity from 10ml to 10L

Ideal for: Food and beverage, hot fill pumpable products, hot fill multi-phase products, and post-fill pasteurization applications

2. FSU800RT: Ultrasonic Sealing for Retort Applications

The FSU800RT is an automatic VFFS packaging machine specifically designed for retort applications. It uses ultrasonic technology to create horizontal seals and hot bar/heat sealing for vertical seals. The FSU800RT is ideal for multi-phase filling of liquids and solids for shelf-stable food products.

Constructed from stainless steel and featuring Clean-In-Place (CIP) controls, the FSU800RT is easy to clean and sanitize. These controls clean the interior surfaces of food and beverage process pipes, processing vessels, tanks, and associated fittings, without disassembling the machine.

Additional features include:

• Stainless steel construction 
• NEMA 4X machine construction with Allen Bradley PLC controls
• Touchscreen HMI
• Filling systems built to sanitary standards
• Ultrasonic sealing for horizontal seals
• Multi-phase filling capability
• Production speed up to 30-35 cpm*
• Package capacity from 10ml to 10L

Ideal for: Food and beverage, hot fill pumpable products, hot fill multi-phase products, and post-fill pasteurization and retort applications

3. FSU800RTC: High Throughput and Production Speeds

The FSU800RTC is a fully integrated VFFS continuous motion machine specifically designed for retort applications but with a high throughput to compete with #10 can filling machines. Its production speed is approximately 50% faster than traditional packaging machines, allowing you to quickly elevate your efficiency and productivity.

In addition to offering higher throughput that competes with canned goods, the FSU800RTC produces flexible packaging that is often safer for the end user. This is especially beneficial for food service operations where food ingredients in #10 cans are used, exposing employees to lids with sharp edges. The FSU800RTC can form, fill, and seal flexible pouches with user-friendlier features like a tear notch, which is easier to use and safer.

Additional features include:

• Stainless steel construction 
• NEMA 4X machine construction with Allen Bradley PLC controls
• Touchscreen HMI
• Filling systems built to sanitary standards
• Ultrasonic sealing for horizontal seals
• Multi-phase filling capability
• Vacuum pull belts with optional servo fill valve
• Production speed up to 45-50 cpm*
• Package capacity from 10ml to 10L

Ideal for: Food and beverage, hot fill pumpable products, hot fill multi-phase products, and post-fill pasteurization and retort applications requiring high throughput

4. FSU800UC and FSU800ESL: Multi-viscosity Liquids for Ultra Clean Applications

The FSU800UC and FSU800ESL are fully automatic VFFS packaging machines ideal for ultra clean multi-viscosity liquid food and beverages with or without particulates. Their automated designs allow for rapid package size changes, eliminating the need to stock different-sized materials.

Developed using deep knowledge of aseptic packaging, the frame and components in product contact are made from 300-series stainless steel for easy cleaning, with filling systems designed to meet the highest level of sanitation for the dairy industry. The FSU800UC and FSU800ESL can both fill single pouches or multiple pouches simultaneously and apply a variety of dispensing fitments or taps. Whether you are packaging beverages or cultured dairy products like yogurt or sour cream, Ultra Clean technology will extend the shelf life of your products while maintaining product integrity.

Additional features include:

• Stainless steel construction
• NEMA 4X machine construction with Allen Bradley PLC controls
• Touchscreen HMI
• HEPA air filtration
• Filling systems built to sanitary standards
• Production speed up to 30-35 cpm*
• Package capacity from 10ml to 10L

Ideal for: Food and beverage, and cold and ambient fill applications requiring ultra-clean environments

5. FSU800HAA: High Acid-aseptic and Extended Shelf Life Applications

Fres-co’s automatic VFFS high-acid aseptic machines efficiently transform rollstock into formed pouches that are filled with multi-viscosity liquid foods and beverages. The custom filling systems are suitable for products with or without particulates and have the ability to fill single pouches or multiple pouches simultaneously for increased efficiency.

The FSU800HAA can apply a variety of dispensing fitments or taps in a sterile or non-sterile environment and can be validated to meet FDA requirements. 

Additional features include:

• Stainless steel construction
• NEMA 4X machine construction w/ Allen Bradley PLC controls
• Touchscreen HMI
• HEPA air filtration and hydrogen peroxide distribution
• Validated by Process Authority to meet sterility requirements
• Vertical seals made with heat sealing
• Production speed up to 30-35 cpm*
• Package capacity from 10ml to 10L

Ideal for: Food and beverage, aseptic fill, and cold and ambient fill applications requiring high-acid aseptic processing or extended shelf life

6. FSU1000A: Low-acid Application for Food, Beverage, and Pharma

At Fres-co, we understand the special care needed to package low-acid products in order to meet all government requirements. Designed to produce flat pouches of low-acid products all under sterile conditions, the FSU1000A is the industry-leading VFFS standard and is suitable for multi-viscosity liquid foods and beverages, and even pharmaceutical products.

It is designed to meet the applicable USFDA Code of Federal Regulations (21 CFR part 113) for thermally-processed, low-acid foods and liquids, packaged in hermetically sealed containers. The FSU1000A’s frame and components in product contact are made from 300-series stainless steel for easy cleaning, with filling systems built to meet the highest level of sanitation for the dairy industry.

Additional features include:

• Stainless steel construction
• NEMA 4X machine construction w/ Allen Bradley
• PLC controls
• Touchscreen HMI
• HEPA air filtration and hydrogen peroxide distribution
• Validated by Process Authority to meet sterility requirements
• Vertical seals made with heat sealing
• Production speed up to 30-35 cpm*
• Package capacity from 10ml to 10L
• Machine options include a fitment applicator

Ideal for: Food and beverage, nutraceutical, pharmaceutical, and aseptic fill applications requiring low-acid processing

Comparison Overview: Choosing the Right Machine

Fres-co packaging machines are specifically designed to accommodate today’s market demand for sustainable packaging solutions. All machines offer package capacities from 10ml to 10L and can accommodate various package sizes. Production speeds vary based on pouch size, product characteristics, and specific machine configuration. 

The table below provides a side-by-side comparison of our machines, helping you quickly evaluate which solution best aligns with your needs:

Choosing A Packaging Partner

As the leader in flexible packaging, we can assess your packaging needs, advise you on materials, develop custom samples, and support you in making the best machine choice. We offer turnkey support with all of our machines, providing U.S.-based parts and technicians, onsite training and machine maintenance, and ongoing support as an advisor that can provide recommendations.

When you choose Fres-co as your flexible packaging partner, you gain advantages that will set you apart from the competition:

• A complete system approach: We provide flexible materials, equipment, printing, and support
• Market-responsive innovation: We work to meet evolving market demands, bringing solutions to the forefront that keep your products competitive and compliant with industry standards.
• Comprehensive machine support: We offer a turnkey approach, providing spare parts, packaging materials, and U.S.-based technicians, ensuring maximum operational efficiency.
• Flexible service options: Choose the service plan that works best for your operation from scheduled maintenance to on-demand service visits 
• A commitment to sustainability: Our flexible packaging options help reduce waste and drive down storage and shipping space requirements

Are you ready to automate your packaging processes? Connect with our team of experts for a one-on-one consultation.

For more than 40 years, Fres-co System USA, Inc. has manufactured high-performance flexible packaging systems and invented dozens of innovative breakthroughs including degassing valves, modified atmosphere technologies, and reclosure systems.

Topics: Flexible Packaging, Flexible Packaging Machines, Liquid Packaging Machines

Moving from rigid to flexible packaging?

Subscribe to Email Updates