The document discusses a form-fill-seal packaging system from NEWPACK for dairy creamers. Key points include that NEWPACK customizes cup shapes and designs efficient machines. The system can include an aseptic version with sterilization processes. Materials discussed include plastic films for cups and aluminum or PET films for lids. Maintenance recommendations are provided. The project process includes testing, teleservice support, and interaction with the client.

2. Overview
TMCI Group
NEWPACK Division
Dairy Creamers
Form-Fill-Seal
Product Dosing System
Aseptic Version (ST)
Materials
Cup Film
Lid Film
Economic Analysis

3. Executive Summary
NEWPACK Global service about thermoforming,
from engineering to after-sale service
Materials
Technical synergy with the suppliers
in order to solve any kind of need
granting best performances and
paying attention to the costs
FFS for Dairy
Creamers
Customisation and machines’ high
level of efficiency
Cups Best attention to shape and design

4. Overview
TMCI Group
NEWPACK Division
Dairy Creamers
Form-Fill-Seal
Product Dosing System
Aseptic Version (ST)
Materials
Cup Film
Lid Film
Economic Analysis

5. TMCI Group
Osman Sagmanli
President & CEO
TMCI Group is a multinational company
based in Switzerland and present with
business units in Italy and Great
Britain.
These business units grant a complete
service all over the world in the
following fields:
wine, beer, soft drinks, oils and
alimentary fats, bakery products,
chocolate and jam, jellies and
processing systems for fruits and
vegetables.
High level of ratio quality-price, client’s
satisfaction, maximum flexibility,
availability of complete lines which are
part of the TMCI Group, a world-wide
leader in his field.

6. TMCI Padovan
Leader in the manufacturing of
processing machines for wine, beer,
tomato, fruit juices.
Turnover: 35 millions €
Employees: 130 people
Certified ISO 9001:2000
New Plant of 12 thousands square
metres in an area of 23 thousands
square metres.

7. NEWPACK Division
• This Division designs and
manufactures complete lines for
packaging
• In particular, Thermoforming
machines in standard versions, also
in ultraclean and aseptic versions

8. NEWPACK Division
Mission:
To give high quality level customised
solutions in order to help our customers
present their products in the best way
and thereby becoming more and more
competitive.

9. Overview
TMCI Group
NEWPACK Division
Dairy Creamers
Form-Fill-Seal
Product Dosing System
Aseptic Version (ST)
Materials
Cup Film
Lid Film
Economic Analysis

10. Your product
NEWPACK customises the cup’s
shape together with the client in
order to get it special.

11. Your FFS

12. Our care for...
- maximum flexibility for the adjustment of
material’s heating temperature (which can be
set on the touch-screen)
- maximum care to the parts to be heated (by
means of heating shaped plates)
- sterilisation of punches and forming
chamber by means of peroxide vapours; use
of sterile moulding air in order to avoid
contamination
- maximum care during the cup forming
phase in order to allow material’s
homogeneous distribution by means of air-
flow adjustment and mechanical punches’
speed adjustment
- mould’s shape realised with CAD/CAM 3D
by a supplier of recognised professional
experience
DATA CODER AND
BRAND

13. Our care for...
- maximum flexibility in sealing plates heating
temperature’ adjustment (which can be set on
the touch-screen)
- speed at the machine’s start by means of a
bronze electrode with high thermal
conductivity
- maximum precision in centring the drawing
on the cup’s lid thanks to the use of an
automatic centring system controlled by a
photocell which reads the guiding marks
- maximum flexibility in welding plates
pressure’s adjustment to allow the using of
the most different covering materials (for
example: aluminium, mixed-paper, metalised
PET, etc…)

14. Our care for...
- using of cutters with high resistance in steel
K110
- maximum flexibility in hydraulic cutting
pressure’s adjustment in order to set the
exact value and so improving the duration
before it must be re-sharpened.
- trimmers especially designed and
manufactured, on the base of the material’s
characteristics and thickness, by a supplier of
recognised experience
- (dairy creamers) possibility of using, without
any problem, thickness from 0,6 mm up to 1,6
mm (upon request we can produce trimmers
who can reach over 2,0 mm)

15. Our care for...
-careful choice of the best dosing system
based on the different kind of products
- (dairy creamers) using of a volumetric
product control by means of calibrated
chambers individually adjustable which
assure a precision of ± 1%
- tank in overpressure with sterile air, to avoid
contamination and create a head which
smoothly conveys the product through the
feeding channels up to the cup
- automatic program for CIP washing and SIP
sterilisation in closed system. Thermostats
for control, placed in correspondence of the
circuit’s cold points, keep the temperature
stable for the pre-set time.

16. Our care for...

17. HEATING Heating, drying, pre-sealing, sealing
STEAM Steam barriers placed on commands to avoid contamination
STERILE AIR Overpressure of the air to keep the environment sterilised
H2O2 Sterilisation of packaging materials by means of immersion
H2O2 VAPOURS H2O2 vapours are in-taken and conveyed outside
PRODUCT
ST: Care for the product

18. -NEWPACK thermoforming machines in
aseptic version are equipped with an
additional unit which allows the pre-
sterilisation of both machine and installations
and keeps the environment aseptic during all
the production cycle.
- pre-sterilisation is carried out through two
separated circuits:
1. Sterilisation of dosing unit and filters by means
of steam for the following production of sterile air
2. Sterilisation of filling tunnel, punches, forming
chamber and conveyors for the distribution of
overpressure sterile air, by means of H2O2
vapours
Aseptic Version

19. - the last two phases of pre-sterilisation are
the drying one and the cooling one at the end
of which the machine gets sterilised and
ready to produce.
- all the phases are controlled and managed
by the machine’s software which, by means
of a touch screen panel, guides the operator
preventing wrong operations or not exact
processing sequences.
- suitable alarms advise in case of
machine’s wrong functioning and
suggest what to do in order to go
back to the optimal conditions.
Aseptic Version

20. -Packaging materials are sterilised during
all the packaging cycle, before getting into
the sterile area.
- sterilisation is carried out by means of an
immersion in a tank with H2O2 with a
concentration of 35%.
- drying devices such as mechanical
squeeze rolls, blows of sterile air and sets
of infrared lamps, grant the complete
removal of H2O2 from the two films after
sterilisation.
Aluminium lid
washing tank
Plastic web
washing tank
Aseptic Version

21. -In order to keep steady the sterile conditions
reached during the sterilisation, it has been
foreseen an overpressure of sterile air from
the heating station to the pre-sealing one.
- in case of oxidisable products inert gases
are used instead of sterile air
- all the mechanical commands which are
inside the machine’s aseptic tunnel are
protected by means of steam barriers, the
temperature of which is constantly controlled.
- the films, before leaving the sterile area for
the final sealing and cutting operations, are
pre-sealed along the edges in order to isolate
the product from the external environment.
Aseptic Version

22. - suction hoods are placed on the machine in
correspondence of:
1. Plastic web washing tank
2. Heating and forming station
3. Filling tunnel
4. Aluminium lid washing tank
- they convey the peroxide vapours out of the
production areas.
- the suction is carried out by means of an
electric fun.
Aseptic Version

23. Maintenance
In order to grant the maximum efficiency in
time, it is necessary to take care of:
• WELDING PLATE
we suggest to control it has a good flatness
and that there are no materials on (with a
machine tool it is possible to get back to the
exact functioning adjusting the surface -
operation suggested 1 time / year - anyway an
additional electrode is always supplied)
• TRIMMER
after a while, depending on the material’s
kind and thickness and his use, the cutters
loose their efficiency (giving the trimmer to a
specialised supplier, it is possible to re-
sharpen the cutters - operation suggested 1
time / each 10 months if they work 8 hours a
day, it means only 1 shift)
Some companies consider the possibility of
having an additional trimmer
• DOSING UNIT AND ASEPTIC EQUIPMENT
seal and filters control (set of spare parts for
dosing unit and aseptic unit are supplied
according to the maintenance plan scheduled)
NEWPACK machines use:
• pneumatic
• hydraulic
• brushless motors
• industrial automation

24. Project development
FUNCTIONAL START-UP IN ITALY WITH TEST
OF THE DIFFERENT MATERIALS’ KIND AND
THICKNESSES
TELESERVICE VIA MODEM WHICH ALLOWS TO
CONTROL IN ANY TIME THE MACHINE’S
FUNCTIONING
DELIVERY OF THE MACHINE WITHIN 5 MONTHS
FROM ORDER CONFIRMATION AND CUP
DRAWING’S APPROVAL
INTERACTION WITH CLIENT DURING ALL THE
PROYECTING PHASE, ESPECIALLY FOR THE
CHOICE OF THE MATERIALS

25. Overview
TMCI Group
NEWPACK Division
Dairy Creamers
Form-Fill-Seal
Product Dosing System
Aseptic Version (ST)
Materials
Cup Film
Lid Film
Economic Analysis

26. the plastic cups film
Polystyrene based barrier plastic materials for cup:
-Medium Barrier
approximated costs 2,50 €/kg
-High Barrier
It is also possible to create
coloured cups in order to
better impress the final client.

27. the lid film
Lid’s material in 3 alternatives:
- ALUMINIUM
- ALUMINIUM with PET
indicative cost 12,00 € / kg
- PET (less barrier effect)

28. Solution 10 ml