As sustainability goals approach, large food and beverage companies are accelerating their investments in sustainable packaging programs. A survey conducted by market research firm GlobalData in April of this year revealed that nearly 35 percent of companies have changed their behavior in the past year to meet sustainable environmental, social and governance goals.

"As the post-epidemic era approaches, consumers are reassessing their consumption behavior and food and beverage manufacturers are aligning their products with the sustainable 4Rs - Reduce, Reuse, Remove and Recycle." Kiran Raj, head of GlobalData's Disruptive Technologies practice, noted. "Sustainability appears to have moved beyond the symbolic meaning of corporate social responsibility (CSR) to become a top priority on manufacturers' business agendas, thereby accelerating the shift to a circular economy."

Nestlé plans to pilot the Neo capsule coffee machine and corresponding capsule coffee in France and Switzerland next year, which differs from previous ones in that it is Nestlé's first paper-shell capsule with a shell that can be used for composting at home and a package that weighs 70 percent less than previous capsules.

nespresso NEO bio capsules
nespresso NEO bio capsules

Nestlé said that after three years of research and development, this home compostable paper-based capsule coffee can be experienced without compromising taste. Nestlé said consumer demand for compostable packaging is increasing, with an estimated 45 percent of French people now composting one or more types of bio-waste at home.

Nespresso CEO Guillaume Le Cunff said, "Pushing the boundaries of the premium coffee experience is part of Nespresso's innovation, and we are more committed than ever to offering consumers a wider range of sustainable options."

Nestlé has also invested approximately $5 million in the Italian venture capital foundation Eureka! Fund to fund research to accelerate innovative packaging solutions, improve the quality of collection and recycling processes, and increase the adoption of recycled food-grade plastics.

Coca-Cola has partnered with O-I Glass, the largest manufacturer of glass containers, to recycle glass bottle packaging in May 2022. Coca-Cola is also partnering with Graphic Packaging International to launch the first U.S. KeelClip paperboard packaging for cans in June 2022 and with Jingdong in January 2022 to support China's circular economy.

Earlier this year, PepsiCo signed an agreement with Carlsberg Group to minimize its reliance on single-use packaging. In June, PepsiCo also partnered with blockchain company Security Matters to recycle plastic.

While recycling is a step in the right direction for companies, it is not the ultimate solution for sustainability, as many recyclable plastics simply cannot be recycled and it takes considerable energy to convert these used products into new ones," said Shagun Sachdeva, program manager for disruptive technologies at GlobalData. With plastics still in circulation and recycled waste ending up in landfills, attention is turning more to green packaging materials."

"While major FMCG companies have set sustainability goals for the next five to eight years, there are still complexities in terms of scale, long-term planning, and slow market adoption that make it difficult for them to easily implement sustainability commitments. But in the long run, it will be interesting to watch how companies will make impactful changes to sustainability on a global scale."

As a leading manufacturer of coffee capsule filling and packaging equipment in China, AFPAK has been committed to providing customers with high-quality equipment and high quality packaging materials, we currently have formed compostable capsule materials and can customize the corresponding packaging equipment for you at any time, come and contact us!

Customize your machine here: https://www.afpakmachine.com/customize-your-own-filling-packaging-machine/

Throughout the years since 2016 RN1S coffee capsule filling sealing machine was designed and manufactured, RN1S coffee capsule filling sealing machine has been the most popular seller because of its special design with a great outlook, highly-enhanced efficiency, user-friendly operating system, space-saving feature, lightweight, the convenience of delivery, simple installation with full guidance, high degree of accuracy, labor cost saved and so much more advantages.

With its commonality, RN1S could process the filling and sealing for Nespresso, K-cup, Dolce Gusto, Lavazza Blue, Nespresso Vertuo, and other customized capsules. Combined with its low-cost feature, RN1S has been continuously preferred by start-ups to medium size businesses, creating value and helping them to penetrate the market, gain new clients and reach a higher level of revenue.

RN1S Coffee capsule filling sealing machine
RN1S Coffee capsule filling sealing machine

The main parts and options of the RN1S coffee capsule filling and sealing machine

Power witch

Compressed air and nitrogen controller

Capsule storage

Stock bin (hopper)

Film storage for film roll

Precision weighing instrument (base + support column + scale)

Cup conveyor belt

Control panel

Vacuum feeding system

Control cabinet including PLC, solenoid valve and other electrical components and main motor

Round plate

functions of RN1S coffee capsule filling sealing machine
functions of RN1S coffee capsule filling sealing machine

The working principle of the RN1S coffee capsule filling and sealing machine

All the filling and sealing work is processed on the round plate in the middle of the machine, which could move clockwise or anticlockwise.

  1. Vertical cup loading.

The cups are packed into the vertical capsule storage tube made of stainless steel. The diameter of the vertical coffee capsules storage tube is can be adjusted according to the cups, such as Nespresso cups, K-cups, Dolce Gusto cups, Lavazza Blue cups, Nespresso Vertuo cups, and other customized cups based on the customer's requirements. The tube could contain over 300 Nespresso cups and 100 K-cups, so to save the loading work for employees.

There are 2 air cylinders controlling the cup loading precisely. It could load 50-70 cups of different types onto the round plate each minute. The diameter of the position on the round plate is designed to match the size of the cup. So the cups could be loaded smoothly and precisely.

The second step is for the RN1S filling and sealing machine to detect if there is cups or capsules placed onto the round plate. If there is no cup or capsule detected in one of the positions of the round table, the detector would send this information to the machine and the filling and sealing process would not be carried out in that position.

The RN1S coffee capsule filling and sealing machine is equipped with a servo motor drive auger filling system with a feeding screw. The function of the feeding screw is to obtain the coffee powder from the silo and transfer the powder to the feeding nozzle at the bottom of the screw through the rotation of the thread.

The cylinder presses the powder suction barrel down to the laminating die. At this time, the powder head fits the mouth of the cup, and the powder in the cup is pressed tightly. The vacuum generator uses compressed air as the medium to create vacuum pressure, and vacuums the powder barrel to suck the powder away from the cup rim. This process ensures a clean filling and it ready for sealing.

Film suction refers to the sucking the film to the cups while film cutting means to cut the film to fit the rim of the cups. Different types of film such as aluminium and plastic films could be used in the filling and sealing machine.

The RN1S filling and sealing machine is also equipped with a film detection device which is used to confirm if the film is placed precisely to the cups.

On the RN1S filling and sealing machine, the cylinder drives the hot sealing head down to press the cup for a short period of time. At this time, under the high temperature of the hot sealing head, the hot sealing coating on the front of the diaphragm melts and sticks to the mouth of the cup to complete the sealing.

The RN1S filling and sealing machine could be equipped with a output conveyor or a scale. The cylinder drives the suction plate to suck the cups and delivery it to the scale for weighing or delivery to the output conveyor for further packing.

Impurity detection of RN1S coffee capsule filling and sealing machine is to ensure that there are no cups in the round plate before entering the next station.

The characteristic of RN1S capsule filling and sealing machine

  1. Highly-enhanced efficiency

50-70 cups can be filled and sealed per minute with ±0.2g filling accuracy。

Controller and operating are simplified so it only takes one operator to run the machine.

The round design of the RN1S capsule filling and sealing machine makes it possible to occupy a smaller floor area of 2 square meters, So it could fit into a normal warehouse within a  house. For startups, it could save a lot of their space, and they can have a few of these models to form a production line to increase productivity.

The machine is light-weighted with the weight about 750kgs. The customer could easily transport by trucks. With wheels, the filling and sealing machine can easily be placed to any area of the customer workshop or factory.

With the clear structure of the filling and sealing machine, it would not take too much effort to install the machine and full guidance would be provided. A hotline will be available to support customers.

RN1S filling and sealing machines have been upgraded continuously to meet the increased demand from customers worldwide. It has helped a lot of small businesses to grow and gain their sales to reach a higher level of their business. Simplicity and efficiency are what Afpak looks for, RN1S filling and sealing machine aims to help clients to improve productivity at a lower cost.

Want to know how many types of coffee capsule packing machines? First, let’s figure out how many types of coffee capsules there are.

It’ll be perfect if you are able to use any coffee capsule in your home coffee maker which means you can taste hundreds of flavors, strengths, and styles of coffee with just one machine.

Unfortunately, as you know, things not work out in that way, and once you buy a machine, you are limited to one type of capsule.

There are so many different kinds of coffee capsules that we have to be careful to distinguish between them, and notice the differences between pods and capsules.

Coffee Pod Or Coffee Capsule

Although there are places where these two items can refer to the same thing even they are often used interchangeably, but actually they are different things.

Coffee pod or pad is a pre-packed dose of ground coffee in a paper filter, and just looked like a round cake shaped tea bag.

It’s divided into two types: soft pod and hard pod.

The soft pod is almost the Senseo pod, which is a bag of untamped ground coffee used to prepare a 80 to 110ml coffee at approximately 2 bar or simply a steep coffee.

The hard pod is also called Easy Serving Espresso (E.S.E) pod, which is well tamped fine ground coffee used to make espresso in pump machines.

However, coffee capsule refer to Nespresso capsules, K-cups, Dolce Gusto capsules, which are ground coffee in plastic, aluminum or bio-degradable material containers with a sealed lid each.

Each type of coffee capsule varies in shape, size and even more.

Coffee Capsule Packing Machine

Let’s define the coffee capsule packing machine as the machine that produce coffee capsules from empty capsule and ground coffee.

There is no doubt that each type of capsule need different packing machine for production.

They either require unique processes or unique methods for specific steps.

But the working principle is the same as mentioned below:

  1. Load empty capsules
  2. Fill ground coffee to each capsule
  3. Clean the edge of each capsule
  4. Load lids
  5. Heat sealing
  6. Output
  7. Nitrogen flush before sealing(optional)

Classification Ⅰ

The coffee capsule packing machine can be classified into two types according to automation level.

  1. Semi-automatic type
  2. Automatic type

Those steps described above are for automatic machine.

Semi-automatic Coffee Capsule Packing machine

If only part of the functions of a fully automatic coffee capsule packing machine are kept, you can get a semi-automatic machine.

It is not difficult to imagine that the machine varies when the kept functions were different in process or number.

They are ideal equipment for starting a small coffee capsule business.

(4 holes semi-auto coffee capsule packing machine - automatic sealing)

(Single lane semi-auto coffee capsule packing machine - automatic filling and sealing)

Automatic Coffee Capsule Packing machine

They are the machines that take care of step.1 “Load empty capsule” to step.6 “Output” full automatically, to minimize human operation during capsule production.

They can simply work as a complete system or connect to additional equipment, such as vibrating capsule sorter, weighting and ejection system, screw feeding machine.

They may have different solutions for each process, such as “Load empty capsules” station, varies from vertical type to horizontal type.

“Fill ground to coffee to each capsule” station, varies from auger filling type to metering filling type.

“Load lids” station, varies from pre-cut lids type to roll film type.

“Output” station, varies from grabbing type to suction type, free fall type, push out type.

They are suit for large scale production of coffee capsules due to their capacities are always over 30 capsules/min.

However, basically one machine can only produce one type of capsule.

(Full automatic coffee capsule packing machine)

Classification Ⅱ

Let’s focus on the second classification method.

The coffee capsule packing machine can be classified into another two types according to the overall layout of all workstations within the machine.

  1. Linear type
  2. Rotary type

Linear Type Coffee Capsule Packing Machine

Linear packing machines have been part of production lines for decades.

These machines keep all workstations in a straight line, complete the filling and sealing process when empty capsules move from one side of the line to another.

They’ll fill capsules in sequence, stop to fill each capsules before moving to the next.

When the capsules complete the filling process, they move to lids placing station, then sealing station, and finally output station.

After one capsule’s output, the mold is empty, it will move to the start of the line to get ready for the next capsule loading.

They always have a rectangular appearance which is different from rotary type coffee capsule packing machine.

They usually operate with one, two, four, or eight heads, even up to twenty to get a higher capacity from 50 to 1000 capsules/min.

(Internal view of a linear type machine - single head)

Rotary Type Coffee Capsule Packing machine

Rotary packing machine keep all the workstations in a circle, complete the filling and sealing process when empty capsules move one round.

They’ll also fill capsules in sequence, stop to fill each capsules before moving to the next.

They’re the same as the linear type machines that the capsules complete the filling, lids placing, sealing and output process in sequence, while the capsule loading station is right next to the output station.

After one capsule’s output, the mold is empty, it will move to the capsule loading station when it passed the “no capsule detection” sensor.

They always have a cylindrical appearance.

They usually operate with one, two or four heads, while more heads is rare.

(Internal view of a Rotary type machine - single head)

The Differences Between Linear Type and Rotary Type

They are different in structure, material, capacity and price.

The different requirements for structure, body material, lead to different capacity and the price is also not at the same level.

Linear type coffee capsule packing machine is slower but cheaper than rotary type, which make it more affordable for a startup company.

However, the rotary machine has improved in terms of structure and performance.

It’s more compact and faster, but on the other hand, more complex and higher demands on maintenance.

When it comes to making changeover to produce different capsules, the rotary machine will be easier, due to easier detachable, less number of mould.

Conclusion

Linear type and rotary type packing machines have their own advantages and disadvantages.

It’s better to choose the right machine which fit your business goal.

AFPAK is a global leader in coffee capsule packing machine area, has an extensive range of coffee capsule packing machines and can offers you one-stop solution.

They also provide customized machines for your specific needs.

Nowadays, they have successfully realized muti-products production in one machine.

To find out more, contact this team.

Are you planning to choose the right coffee capsule packing machine, but you don't know how to start?

Many of my clients are in the same situation, asking for advice from the salesman from the very beginning.

Here we will guide you in choosing the right coffee capsule packing machine.

In my opinion, instead of asking for a quotation directly, it is better to start by asking yourself first, what’s your real needs, and then target your search for a machine.

So, let's figure out this thing in two steps.

Step 1: Find Out Your Real Demands

Which kind of capsule?

I listed some usual demands of the capsule type our clients requested.

·Only one specific capsule: aluminum Nespresso capsule or others

·Only Nespresso, but both aluminum and plastic, even the third material

·Both K-cups and Nespresso in one machine

·Three types of capsules or more

Different demands of the capsule type have different requirements for the machine structure.

Sometimes you need to purchase more than one machine due to so many types you want to put into production that it’s very hard to realize in one single machine.

So, you need to determine the capsule type first, including the material.

You need to note that even though both are Nespresso compatible capsules, aluminum is a little different from plastic, A company’s plastic is different from B company’s in dimensions.

Besides, you may also need to know the properties of each material, such as oxygen barrier, vapor/moisture barrier, leakproofness, sealing performance, etc.

If you can decide the empty capsule supplier and the specific capsule model from the very beginning, that’s the best.

Of course, we do not exclude that there are some clients seek machine quotations while seeking quotations for empty coffee capsules to calculate the cost of each finished capsules, then decide which is the target capsule type.

(Which is your target?)

Which kind of sealing film?

If you have decided on the capsule type, then perhaps you have also decided on the sealing foil to be used, or maybe not.

Sometimes these two things don’t come from the same supplier.

If it’s aluminum capsules, basically it’ll be fit with pre-cut aluminum foil.

If it’s plastic capsules, it’ll be fit with plastic or aluminum film, pre-cut or roll film.

If paper/bio capsules, basically bio-degradable film in roll stock.

One other thing is, do you want to have the logo printed on the film.

If yes, you also have to design a print pattern in advance, then communicate with the film manufacturer and ask them to produce the film with your design.

You need to pay attention that generally the film with your logo printed on, MOQ is relatively large.

There is one special situation that the machine would be used for contract production for various coffee roasters with their own logos printed on film, and in this case a good film supplier would be particularly important.

If you also want to print the date of manufacture on the film, then you will also need to contact the printer manufacturer if this is feasible.

It is important to note that the ink used for printing on the film sheet must be food grade.

(pre-cut film & roll film)

Expected production?

Maybe you've already taken several wholesale bookings from your clients, so you are aware of the volume of production for the next few months or even years.

Or maybe you just have the idea of producing coffee capsules because you saw a certain market.

In either case, an estimate of the expected production is required.

Production speed is an important parameter of a packaging machine and a factor that will raise your budget.

So determining the production speed you want beforehand will actually allow you have a reasonable budget.

Of course, if you have a more optimistic estimate of the market, you can try to choose a slightly faster machine for the future.

Other expectations

Accurate filling weight is the guarantee of good quality coffee capsules.

Each machine manufacturer makes different efforts in this area, like the structural design and the components used.

One way to verify accurate filling weight can be as follows: after a long trial production, do random sampling, and weigh them to calculate the deviation from your expected filling weight.

Robust sealing is also the guarantee of good quality coffee capsules.

One way to verify good sealing quality can be as follows: after a long trial production, do random sampling, visually check whether the sealing surface is neat and tidy, finger press to see whether it is firm, and then leak-proof test.

Oxygen content affects the shelf life of capsules.

You can ask the supplier to do oxygen level test if you have a requirement for this.

Step 2: Request For Quotations

Well, the next step is request quotations in a targeted manner.

Since you have considered enough details prior to this step, things will be simple.

The quoted prices may be a little different, but generally no much deviation.

Each quotation may looks as similar to each other, making it difficult for you to make a judgment.

There are actually many factors to consider beyond price like the following.

By the way, if you don't know how to do step 1 at all, then there is another option that you consider doing both steps at the same time.

All your demands be met?

There are several points based on which you can find out whether your functional requirements can be met?

·You can tell that they have experience on this special capsule and unique function.
·There are customers in the local area who produce similar products as well as that you can pay a visit to.
·You think they had the best solution among all the suppliers.
·They can provide sufficient test evidence during machine building.

If you have a budget on this project, then you may need to make concessions on some functional demands eventually.

If you have limited space in your facility, then the dimensions of the coffee capsule packing machine is something you need to pay extra attention to.

Brands of the core components

As you know, core components affect the price and performance of the coffee capsule packing machine.

And generally the brand and model of each component should be clearly documented in each quotation.


·Schneider from France or OMRON from Japan ------ Normal configuration


·OMRON ------ Normal configuration


·OMRON ------ Normal configuration


·Schneider or OMRON ------ Normal configuration


·OMRON or Panasonic from Japan ------ Normal configuration


·Schneider ------ Normal configuration


·OMRON or Schneider ------ Normal configuration


·AirTAC from Taiwan ------ Normal configuration
·SMC from Japan ------ High configuration, expensive

(Core components)

How is the training?

Although the fully automatic coffee capsule packing machine is very intelligent but doesn’t mean it’s simple enough to operate directly by anyone without any acknowledgment.

As far as I know, at least at several points, you need some training soon or later.

·Installation
·How to change filling weight when using different coffee powder
·How to change molds to produce another type of capsule
·What are the meanings of the warning messages
·Dairy maintenance

The more function the coffee capsule packing machine has, the more training you need.

It’s important that enough training was provided before the real production.

How to perform final goods inspection?

Generally speaking, there are at least three kinds of final goods inspection methods.

·By photos and videos provided by vendor when the machine is finished
·Field inspection by yourself
·Field inspection by third-party inspection agency

While the first one is the most common, and the least costs.

However it should be noted that if the video continuously records the production for tens of minutes, especially while the machine used your capsules and films, it’ll be more convincing.

And in my experience, how to perform the inspection, even do or not do, you need to take the initiative rather than waiting for the machine provider.

How to perform maintenance?

You should focus on how to perform preventive maintenance rather than corrective maintenance which means what to do when machine failed.

·Which parts need to clean, in what frequency
·Which parts need lubrication, in what frequency
·Which parts need to change regularly
·How to inspect the machine regularly
·When can I cut down the frequency of inspection

As for how to perform the maintenance caused by machine failure, it’s better that you ask for help from supplier directly, which needed to be checked with the supplier
whether this is possible.

What after-sale service will be provided?


·One year ------ Normal
·Two years ------ Outstanding

Generally speaking, you’ll take care of the installation and usually no problem with that, but it’ll be helpful if the supplier can provide sufficient information before the installation.

Similar to machine installation, you’ll take care of the commissioning before real production.

You can take it as part of the training, so it is also important that the supplier can provide adequate support.

The machine supplier is obliged to inform the individual wearing parts as well as ensuring one or more sets packed with the machine.

Besides, the supplier need to commit to providing replacement parts in time even out of warranty period.


·Adequate technical support in daily maintenance and troubleshooting ------ Normal
·Local maintenance staff available ------ Outstanding


·Within 24 hours ------ Normal
·Within 8 hours ------ Outstanding

Payment terms?

It’s tens of thousands of money that should means something to you, so it’s worth trying reducing risk in payment terms.

But what I'm trying to say is that rather than dwelling on this point without compromising, how about choose a supplier with good credit.

·30% deposit in advance and balanced before shipment ------ Normal
·30% deposit and balanced on sight or 30 days after arrival ------ Outstanding

Summary

When you are going to expand to coffee capsule business and want to purchase a capsule packing machine, go ask yourself or consult the machine supplier about these.

·Capsule type
·Foil lid type
·Production speed
·Price & lead time
·Filling accuracy
·Sealing quality
·Oxygen content
·Brands of core components
·Training
·Final inspection
·Maintenance
·After-sale service
·Payment terms

Some of the coffee capsules we produce are for retail sale and are expected to be consumed in a short time.

In this case, the shelf life of coffee capsule need not be too long.

However, some are expected to be wholesaled or may be placed on supermarket shelves for a long time.

In this case, longer shelf life is required.

How is the Shelf Life of Coffee Capsule Determined

Every coffee has a peak post-roast period and should be consumed during this time if you want to enjoy its best flavor.

For some coffees it's just several days, for others it may be as long as several weeks.

Ground coffee is a dry food and just like most dry goods that doesn’t actually go bad, but if it’s left too long after its peak, its flavor or freshness will start to be lost and turn out flat.

This is called shelf life, and it is closely related to freshness.

Roasted coffee has four traditional enemies: oxygen, light, moisture and heat.

Even though it should be given some time to "breathe" after roasting, which means it was allowed for exposure for a period of time, but if it lasts too long can quickly cause lost of its freshness.

Factors That Affect the Shelf Life of Coffee Capsule

The process of packaging was invented to make it easier for food to last longer on the shelf, but the length of that time depends on a number of factors, which can be the coffee capsule packing machine or package material or the storage environment, and the packer must pay close attention to.

Grinding

Actually the first thing we should pay attention to is one step prior to packing: grinding.

Part.1: Grind size and grind quality

You can only achieve a proper and stable coffee extraction in a short 20 seconds brew time when respect to both grind size as well as grind quality (variation around desired average particle size).

If the size of ground coffee particle is different from each other, the surface area in contact with the water during each brewing will change (the substance extracted at each brewing will not be stable), then ideal uniform extraction cannot be achieved.

In any brewing application, the goal of grinding is to achieve the exact same and ideal size coffee particle.

however, this is not possible due to the mechanical limitations of any type of coffee grinding equipment.

Therefore, instead, we aim to maximize the "fit-to-size" particle fraction and minimize the variance of the other coffee particles from the desired average particle size.

Since the grind size affects the taste, and the taste is also a measure of shelf life, so it’s the first factor that we should pay attention to.

Part.2: Timing

We all know the degassing process which refers to the gases releasing from roasted coffee.

When you roast coffee, gases -- including large amounts of carbon dioxide -- form inside the coffee beans.

In one book called Espresso Coffee: The Science of Quality, the author estimates that the release of carbon dioxide is directly related to the loss of volatile substances.

Release 50% carbon dioxide and half of the aroma will disappear and the darker the roast, the greater the loss, he wrote.

In most cases, once the coffee is roasted, you only have 2-3 weeks to experience its optimal freshness and flavor.

For fresh ground coffee, it takes only 30 minutes to get to the point where the freshness drops off quickly and noticeably.

Research shows that some ground coffee loses most of its aroma after 30 minutes.

Each coffee may be a little different, but what is certain is that you need to choose the timing of the grind based on your experience and fill the coffee grounds into the capsule quickly.

For professional coffee roasters who produce their own capsules, it is very important to keep the time between grinding the coffee and sealing the pods as short as possible.

Container

Packaging containers (capsules) come in different shapes, materials and designs.

All of these combine to play an important role in ensuring that packaged coffee granules last as long as possible.

A good container which can gives the coffee powder a long shelf life must protect them from exposure to light, moisture and oxygen.

Aluminum capsules tend to offer the best barrier properties because they are impervious to water and air and protect the coffee from aroma loss. Plus, they are 100% recyclable.

The PP plastic capsules tend to offer good barrier properties to light and moisture, but not a good barrier to oxygen, so can’t be used for long time preservation directly.

While the PP + EVOH + PP multi-layer structure plastic capsules effectively solve the defect of poor oxygen barrier properties.

The PET or PBT plastic capsules also tend to offer good barrier properties to light, moisture, and oxygen, it’s very suited for long time preservation.

The PLA plastic or other bio-degradable materials tend to offer a poor barrier to moisture and oxygen, but the good news is that recently there are some companies solved this problem.

of

Packing Process

The packing process is very important to the shelf life of packaged coffee.

The single-use of packaging actually helps the capsules stay fresh because the seal is only broken when the coffee is used, rather than being reused like a one-pound bag.

Coffee capsules do not require a complicated packing process, as long as they are well sealed.

The bottom line is to keep the product free from contamination, safe and stable during the packaging process.

Therefore it’s essential that the coffee capsule packing machine is made of 304/316 food-grade stainless steel in the part which contact with coffee, and it has a stable filling weight and sealing quality.

Meanwhile, nitrogen flushing creates an improved atmosphere inside the pods that can keep coffee for up to 6 months.

Each capsule is flushed with nitrogen to squeeze out oxygen, and if it’s possible, vacuum outer sealing can maximize the isolation of oxygen, light, and moisture.

Storage

After looking at all the other factors, the final piece of the puzzle is the storage environment.

If the storage environment is wrong, even if you get other things right, everything can go to waste.

You have to take into account temperature, cleanliness and air humidity.

High heat and high humidity environment will make food spoil faster.

So, make sure storage areas are clean, dry and open.

Studies have shown that a 10°C increase in temperature increases the rate of deterioration by 15-23%.

However, that doesn't mean you should store your coffee capsule in the freezer.

The humidity can cause moisture to seep into the package.

A not hot, not bright, and dry place like a pantry or cupboard may be a good choice.

Avoid placing in warm places such as right above or near to the oven or in cabinets that are hot from exposure to sunshine or heat from cooking equipment.

Conclusion

There are some tips to increase the shelf life of the coffee capsule you’re producing or using that are described in this article.

·Pay attention to grinding quality and timing

·Choose the capsule which has excellent barrier properties

·Choose a coffee capsule packing machine with good sealing quality

·Use nitrogen flushing during capsule produce

·Ensure a good storage environment

We’ll mainly distinguish different types of Nespresso capsules by their material here.

As we all know, Nespresso capsules can be made from many different materials, which directly affect the taste of coffee and also our environment.

At the same time, these different materials also make a difference to the structure of the coffee capsule packaging machine.

Widely used materials are divided into three categories: aluminum, plastics, and compostable(plant-based) materials.

The aluminum capsules generally refer to the Nespresso pods of Nestlé, while other brands and coffee roasters have been slowly adopting this form.

However, the plastic capsules can be Nespresso, Keurig, or other forms.

That being said, generally, Keurig capsules were made up of three main elements -- the plastic cup itself, the paper filter, and aluminum foil.

Also, the compostable capsules can be Nespresso, Keurig, or other forms.

Then how does the material or structure of the capsules affect the taste of coffee or our coffee drinking experience?

And what exactly are the differences between these materials?

Aluminum Capsules

The aluminum capsules were fully airtight, and light-tight that they were used to protect the quality and freshness of our coffees from the exposure to oxygen, moisture, and light.

It is capable to protect the unique aromas and flavors of our coffee, making our coffee has a stronger taste.

It is also robust, yet lightweight.

All these functional advantages which surpassed others made it remains our material of choice for packing coffee.

Besides, it is 100% plastic-free and totally recyclable.

When it comes to the effects to the coffee capsule packing machine, because of the good thermal conductivity of aluminum film and cup, this kind of capsule requires a higher quality heat sealing system.

Source: https://www.afpakmachine.com/project/aluminum-nespresso-capsules/

Plastic Capsules

Today, most coffee capsules are made of food-grade plastic, with a plastic or aluminum foil lid.

Similar to aluminum capsules, most plastic capsules are airtight, lighttight, sealed in an low oxygen environment, keep the coffee inside for long time freshness.

They are also recyclable, after rinse the brewed coffee grounds and separate the foil lids from the capsules.

But normally coffee brewed in plastic capsules has complex flavors and different textures, mostly depending on how the coffee is roasted.

There are actually many different materials of plastic capsule on the market, each with different characteristics.

PP (Polypropylene)

PP is a highly transparent and crystal clear material which enhance the image of any product inside.

Coffee in the PP capsule will be highly protected against moisture and steam to maintain freshness and taste.

Generally PP plastics is similar to PE, but more stronger, and more expensive.

·Transparent

·Greater resistance to chemicals, heat

·Strong and hard to break

·Rough surfaces may cause scratches

·Outstanding vapor and moisture isolation

·Slightly inflexible

·Poor oxygen isolation

PP types of nespresso capsules
PP types of nespresso capsules

(PP Nespresso capsule)

PE (Polyethylene)

PE plastic is soft, durable and tear-resistant which perfectly suit for packing heavy items.

Therefore many industrial companies often utilize PE storage bags to package large, heavy industrial machined parts.

·Inert, lighttight, and produces low static charge

·Significantly less attraction of dirt, dust or other foreign matters

·Soft and elastic

·Great resistance to low temperatures and abrasion

·Poor oxygen isolation

·Generally speaking, the price is lower than PP

PET (Polyethylene terephthalate)

PET plastic is normally light weight, high transparent, good impact resistance and breakage resistance.

PET bottles became the main packaging material for beverage products today.

Especially those beverages which require high temperature sterilization filling, such as flavored water, juice, sports drinks, etc., are also packaged in PET bottles.

With its heat-resistant and pressure-resistant features, it has replaced various PVC bottles, bags, aluminum capsules, iron cans, glass bottles, etc., and has become the packaging material with the most growth potential.

·High oxygen and moisture isolation

·Strong and lightweight, higher strength and stiffness than PBT

·Lower moldability than PBT

·High heat resistance and pressure resistance

·Wide range of use temperature, from -60 to 130°C

·Practically shatter-resistant

PBT (Polybutylene terephthalate)

The majority of plastic coffee capsules today are made from PBT, with aluminum foil lids both on the top and bottom.

It’s very similar to PET capsules in many ways, with only a few difference.

·High oxygen and moisture isolation

·Strong and lightweight, slightly lower strength and stiffness than PET

·More elastic and tough (higher impact strength) than PET

·High heat resistance and pressure resistance

·Slightly lower melting point than PET

·Robust chemical resistance like PET

·Relatively hard to seal like PET

PBT types of nespresso capsules
PBT types of nespresso capsules

 (PBT Nespresso capsule)

PLA (Polylactic acid)

Different from all the above materials, PLA capsules are an eco-friendly plastic in packaging, made from compostable materials such as cornstarch or sugarcane.

There are data shows that the carbon emissions of PLA production is 68% smaller , and the energy usage is 65% less than that of conventional plastics production process.

The PLA skirt and the recycled aluminium or bioplastic film on top make these capsules an ecological choice.

·Environmentally friendly

·Poor oxygen and moisture isolation

·Relatively low strength

·Low heat resistance, toughness

·Available in a wide range of composite materials and colors to provide different performance and appearance

plastic types of nespresso capsules
plastic types of nespresso capsules

Source: https://www.afpakmachine.com/nespresso-compatible-pla-coffee-capsule

PP+EVOH+PP

The PP sheet with added EVOH barrier material is widely used in the food packaging industry, it can effectively block the penetration of water, oil and oxygen, and prolong the shelf life of food.

PP is considered to have outstanding vapor and moisture barrier properties but poor oxygen barrier properties.

However, EVOH is considered to have superior gas barrier properties on condition that not exposed to moisture. And it is more expensive.

This materials combination was not only used in coffee capsule packing, but also foods packing in supermarkets and other places.

High barrier nespresso capsules
High barrier nespresso capsules

(PP+EVOH+PP capsule layout)

Compostable Capsules

Compostable capsules are made from a variety of renewable raw materials, should biodegrade within several months in commercial composting, and can be added to local food waste collections.

Despite its eco-friendliness, there are still various challenges remain for biodegradable materials towards practical packaging applications.

Particularly with the poor oxygen/moisture barrier issues.

Therefore the compostable capsules are usually packaged in nitrogen-filled airtight bags in order to maintain coffee freshness.

Basically compostable capsules are made from the following raw materials.

·Wood bark/lignin

·Sugarcane/sugarbeet

·Cornstarch

·PHA (bacteria-based bioplastic)

By the way, PLA plastic capsule is also compostable.

wood bark types of nespresso capsules
wood bark types of nespresso capsules

(Wood bark based capsule)

sugarcane based types of nespresso capsules
sugarcane based types of nespresso capsules

(Sugarcane based capsule)

Recycling Process

Nowadays people care about environment and used coffee capsules recycling.

Thankfully, most of them are traditionally recyclable, which means they can be recycled like other plastics and metals.

Most coffee capsules contain four materials: plastic, aluminum, compostable material, and brewed coffee grounds.

All four of these materials can generally be separated, sorted and responsibly recycled.

Aluminum capsules

The beauty of this material is that it is 100% infinitely recyclable.

It does not lose its technical properties even recycled for many times.

It can be used repeatedly, which is why over 75% of aluminium production is still in use today.

You'll need to pierce the foil lid, dump out the used coffee granules (either in your food bin, compost, or other reuse methods), and do a quick rinse before adding it to your recycling bin.

Or you can just ship them back to a Nespresso recycling facility using a given recycling bag with a prepaid UPS shipping label.

Or simply drop the bagged capsules off at your local Nespresso boutique or participating store.

What happens to recycled aluminum?

The aluminium recovered from our capsules is reused to make a wide range of products, from beverage cans to car parts, bicycles and other everyday useful items, and even new Nespresso capsules.

Producing aluminum from already used aluminum can save 95% of energy.

The empty plastic recycling bags are recovered and converted into usable energy.

Plastic capsules

The plastic capsules are made of PP, PBT, PET, etc. that they are 100% recyclable.

However still in some place they may only be recycled in specific situations such as if they can easily be separated from other recycled materials.

How exactly to recycle?

The easiest option is to use Keurig's mail back recycling program for Keurig capsules or TerraCycle coffee capsules zero waste box.

In this case, you don't have to separate the plastic from the filter, foil lid, and coffee grounds, but just throw the used pods in the box.

Or you can check whether there are Terracycle dropboxes at Subaru dealerships that take coffee pods which always don’t matter brands.

The most conventional approach is that you probably need to first check with your community about local recycle program.

If they do take plastic pods in the recycling, then you can procedure these steps.

·Peel off the aluminum cover

·Separate the inner paper filter from the outer plastic cup

·Keep cups and other recyclable plastics together or just put cups in your regular bin if sorting isn't required in your area

·Put aluminum cover to other recycling bin or collect them together for next time

·Compost filters and coffee grounds

Compostable capsules

It’s an ideal option in dealing with recycling.

You can throw it in your home compost or green waste bin.

Or you can take it to your local community compost yard.

If it ends up in a landfill, it will still break down over time, just not as quickly as it does in compost.

Summary

We divided the coffee capsules into three categories by material in this article, and talked about how is the way to recycle them individually.

There may be some difficulty in recycling coffee capsules in your local, but do be patient and do it.

I also hope this article can be a reference to your selection of coffee capsules when you are preparing for mass production.

How To Perform Maintenance For A Coffee Capsule Packing Machine?

It is no doubt that no matter what kind of machine you own, you need to make sure it is well taken care of, especially for large machines like coffee capsule packing machines.

Maintenance can be treated as one kind of risk management that plays an important role in maintaining optimum productivity.

It is so important that some companies have made very detailed and informative maintenance plans for their equipment.

We’ll start with some easy and basic points, and then cover it later in this article about how to make detailed maintenance plans.

Five Tips For Coffee Capsule Packing Machine Maintenance.

  1. Lubrication

As the first thing you need to consider for machine maintenance, which is also clearly described in the machine manual, it’s very important that those moving parts of the coffee capsule packing machine must be kept regularly lubricated with a drop of lubricant.

And if it’s ignored, the defects caused by friction are usually not covered under warranty.

If the machine is covered with dust, dirt or some coffee powder, it is unpleasant to use, it may also lead to some potential problems during the running. 

Simply do some cleaning at the end of the work will make a lasting impact on preventing big problems later on.

Empty the dust box at the “suction powder” station in time, and clean the heat sealing head everyday.

Regular cleaning can prevent the prolonged downtime associated with less frequent maintenance.

It’s also important that the machine is kept dry.

Remember to dry the machine after the cleaning, and place it in a dry place.

The coffee capsule packing machine has components designed to cut, such as the cutter of the “vertical capsule loading” system or “film cut & heat sealing” system.

Keeping the sharpness of them is critical.

Especially the cutter in the “film cut & heat sealing” system, probably stuck to some roll film debris after a period of running, causing the blade to become blunter.

If this is ignored, may lead to cutting film not good or even failure.

It’ll be very effective if you can do the sharpening weekly.

As we all know that wearing parts exists in almost all the machines.

Regular replacement of wearing parts is required to avoid slowing down or complete failure of coffee capsule packing machine. 

If this is ignored, when the damaged elements failed the machine’s running and even inhibit the production line, It will be very bad.

Besides the damaged parts could only be detected or replaced by highly qualified and trained person or certified service technicians. 

Therefore, at first you take a inventory of high wearing parts and moderate wearing parts, then make clear of the process and schedule for replacing.

You should be in good communication with your supplier about these parts.

Regular inspections play an important role in machine maintenance for ensuring your machine’ long life span.

You can make a schedule for these inspections described below:

·Check whether the chain is loose

·Check whether some other parts is loose

·Check for abnormal sound

·Check if the motors are overheating

·Check the sealing quality by random sampling

·Check the weight of the whole capsule by random sampling

Perform these routine inspections to ensure that the machine is in a well condition.

Four Types Of Coffee Capsule Packing Machine Maintenance

All right, let’s dig it deeper.

We’ll go through a group of theoretical knowledge about machine maintenance first, then use this knowledge to improve our maintenance skills and learn how to make a detailed coffee capsule packing machine maintenance schedule.

At first, there are basically four types of maintenance strategies.

  1. Preventive maintenance

Preventive maintenance(PM) is based on the philosophy that "An ounce of prevention is worth a pound of cure". 

PM is performed at predetermined intervals or according to prescribed standards, designed to reduce the risk of failure or performance deterioration of equipment.

It helps you find and fix small issues early by scheduling inspections and tasks before they become big problems.

It helps reduce the possibility of unexpected failure or equipment breakdowns.

PM can be as simple as doing a weekly check, a cleaning, a drying, a lubrication, or replacing an element once it has done some number of run-hours just like the tips mentioned above.

Corrective maintenance(CM) is based on a firm philosophy that, in the event of a failure, downtime and repairs cost less than the investment required for a maintenance program.

Therefore repairs are carried out after an abnormal condition appears, with the purpose of getting back to the normal conditions.

This strategy seems to be cost-effective before a disastrous failure occurs.

But risks and benefits coexist.

Risk-based maintenance(RBM) is based on risk and cost analysis, aims to determine the preventive maintenance strategy by seeking the more reasonable cost of all the risks.

Risk analysis is like this.

·Which part could go wrong?

·The possibility of this problem occurs?

·What influence will this problem cause?

Cost analysis is like this.

·Direct cost. Such as routine preventive maintenance cost.

·Indirect cost. Such as organizational, management cost.

·Consequence of failure cost. Such as safety cost, delay of production cost.

Condition-based maintenance(CBM) is based on the device performance monitoring, and the corrective actions will be taken accordingly.

By detecting important operating equipment parameters, to achieve continuously monitoring of the equipment conditions is every important in CBM.

Maintenance occurs when certain signal shows that equipment is worsening and the probability of failure is increasing.

So in the long run, this strategy can reduce machine failure associated maintenance costs, meanwhile minimize the occurrence of critical failures and optimizing the management of available economic resources.

Advantages and disadvantages of PM

In a word, its advantage is that it avoids as much trouble as possible before it turns to machine failure. 

When you perform maintenance in this strategy, you know what the maintenance team will do in a certain day, you have plenty of time to prepare for it. 

Because you have already arranged the work in advance, you can easily send the right guy there at the right time, instead of having to call special technicians to deal with it. 

Because you can schedule maintenance to avoid peak production periods, you won’t get confused in such critical times.

On the other hand, its disadvantage is the possibility of straying into the over-maintenance misconception that you're doing more than you need to.

Can good things be eaten too much? In terms of maintenance, it’s possible. 

The two big problems are additional waste and increased risk like these below.

If you replace the fan belt on the engine too soon, you're probably throwing away perfect stock.

And every time you open the control cabinet and have a technician take parts out and put them back after check, there is a risk of accidental damage.

A technician might strip a bolt or drop a metal tool in the distribution box.

Even something like checking the circuit can introduce foreign matter into the machine.

Advantages and disadvantages of CM

In a word, its simple and save time.

CM only plans maintenance for equipment when it breaks down.

There is almost nothing particular to do until a problem occurs.

It usually reduces short-term costs because a lot of the planning and preventive maintenance work were eliminated.

If the equipment had almost no problems, the maintenance cost was about zero.

It’s the best choice when the equipment is not very expensive or important, or when the time and money required to perform PM is much greater than that required to perform CM.

Despite its advantages, CM also has some disadvantages.

Since little preparation is done before the failure occurs, and there is no advance prediction of what the upcoming problem will be, there is a possibility that something unexpected will happen which increased risks.

Unexpected failure may cause disastrous damage to the whole system.

And generally speaking, it may be too late when finally the equipment failure occurred.

Advantages and disadvantages of RBM

In a word, RBM can reduce risks to acceptable levels.

Since almost all the risks have been analyzed in advance, so the equipment owner can take precautions for risks they think they need to avoid based on their own conditions.

For higher level risks, the frequency of PM or CM may be increased, while for those with lower levels of risk, less or no maintenance will be done.

It’ll eliminates work which seems to be low-value, and provides guidance for limited budgets at the same time.

On the other hand, its disadvantages are obvious.

One is that risk identification and analysis processes is the basis so failure in this link will be enlarged.

There may be unrecognized risks involved and risks that are assessed to be too low which will lead to unexpected results.

Therefore the risk identification and analysis processes is emphasized and may take too much time or spend too much budget.

And its difficult to identify and select the right man for risk assessment.

Besides, risk assessment can be based on too subjective standards due to the lack of reliable objective standards and in that case it is quite common to trust an expert’ judgments.

Advantages and disadvantages of CBM

In a word, you can keep the device running and let the sensor work for you when performing CBM.

CBM takes place while the equipment is running, instead of shutting down the device to check, which saving you overall downtime. 

You can just perform tasks when you realized you need them, instead of having to schedule as many inspections in advance, which save on overall maintenance costs.

Being able to "see" the condition of equipment without having to turn it off and disassemble parts to check saves you more than just time and effort.

You'll only need to send a technician up to check if you already know there's a problem which indicated by a sensor.

It may also protects you from the risk of equipment damage and injury to technicians.

About disadvantages, the first thing is cost.

This includes both the equipment required and the additional training you will need, which will make you know how to set up and calibrate the sensors.

Besides, this strategy’s basis is that you need to choose the right sensors for the equipment at first.

Even with the "right" sensors, you could still be in trouble if the environment is harsh enough to eventually destroy them, or the sensors themselves may also run into a failure.

Maintenance Types Summary

Choosing the right maintenance strategy starts with understanding your options, their long points and weak points.

Run-to-fail tends to have a bad reputation, but it's the best option for some equipment.

Actually you can use it when something is difficult or impossible to maintain, but cheap to stock, easy to replace elements.

PM helps you find out potential problems early by scheduling inspections or eliminate some risks before they come out through the daily care.

RBM helps to reduce risks to acceptable levels and cares about risk analysis in advance.

CBM relies on sensors and special software to collect data of the equipment, which will be continuously monitored till the readings exceed preset parameters.

So in the end, there is no one-size-fits-all perfect strategy.

There are someone choose run-to-fail, and also someone choose PM.

Rather than considering various strategies in isolation, look at the differences between them to better understand them.

Actually, instead of having to choose the one that suits you best, you should choose the right mix of maintenance strategies for your coffee capsule packing machine.

How This Theoretical Knowledge Helps Us?

Let’s refocus our attention to coffee capsule packing machine maintenance.

In my opinion, you can try to flexibly use the combination of PM, CM, CBM in performing maintenance of this machine.

You can schedule your own coffee capsule packing machine maintenance work like this below.

When the machine was just arrived and started to work, its a new machine, the operation is not familiar to you, it has much uncertainty, in this initial period, all three of them need to be performed in a higher frequency.

Timely cleanup of dust, lubrication, such PM work is essential.

In addition, you need to strengthen the monitoring of the operating results, like filling weight, sealing quality, to achieve the early detection of problems or problem trends, these CBM work is also essential.

This period can be up to one or two months after the machine first started running.

After a period of use, machine performance tends to stabilize, you can appropriately reduce the frequency of some CBM, maintenance strategy can be based on PM plus CM.

PM is still the basis of normal production every day, and you can try run-to-fail strategy in this period.

After the machine has been running for more than five or six years, all the parts have aged more or less and they are not longer performing very well, you need to strengthen PM and CBM, just like the machine was at the beginning.

Some parts may have to be replaced in time to greatly reduce the probability of errors.

In addition, the results of the machine operation can no longer be fully trusted, and more detection is needed to find out errors early.

Summary

You can basically schedule your coffee capsule packing machine maintenance work like the following.

·Initial stage(1 or 2 months since your machine started work)

- Perform PM, CBM at a higher frequency

·Stable running stage(5 or 6 years)

- Perform PM in a normal frequency, plus CM

·End stage

  - Perform PM, CBM at a higher frequency

As for the PM schedule, get suggestions from your supplier.

And, keep in mind five tips of PM work.

·Lubrication

·Keep the machine clean and dry

·Keep some parts sharp

·Change parts regularly

·Inspect machine regularly

Ways to Combat Dust in Coffee Capsule Packaging Process

Even with the most advanced capsule packaging technology, dust and various particles in the air are unavoidable

In particular, coffee powder, using different roasting processes and degrees, resulting in a great difference in the granularity and moistness of the coffee powder, in the process of packaging coffee capsules, the use of improper dust control means may be counterproductive.

Smile dust leakage is most likely to occur when the dry coffee product passes through the different stations of the coffee capsule packaging machine. During the coffee capsule production process, there is a risk of increased coffee particles in the air whenever the coffee powder continuously moves through the machine, or when the machine is turned on and paused.

Here are eight features of modern powder packaging machines that can help reduce or eliminate the negative effects of dust in your automated packaging line:

The following AFPAK coffee capsule packaging machines are designed to help you reduce or eliminate the problems caused by dust in the production of coffee capsule packaging through various means and materials

1. Enclosed machines body

If coffee capsules are produced in an open environment, dust in the absence of any group will fill the entire space, so a closed mechanical structure is crucial, and the closure of the different components cannot be ignored, they can be a barrier to block the dust, but also the function of cleaning the dust, protecting the filled coffee from contamination also the coffee powder will not evaporate in the air.

Air quality and humidity also have an impact on the filling of coffee capsules. Our design needs to maintain the original dryness and humidity of the coffee so that moisture and dust in the air do not come into contact with the coffee material for long periods of time, which has an impact on the filling and taste.

2. The role of dustproof housing

We use a dustproof housing using a combination of plexiglass and stainless steel, which can effectively protect the electrified components and equipment from collisions and dust so that the machine can run for a long time, any function is basically unaffected by the environment, climate, air, some of the extreme cases, because of the difference in air pressure only need to adjust the machine parameters. Basically, coffee capsule packaging can be done anywhere in the world.

3. powder suction equipment

During the production of coffee capsules, it is not only necessary to consider dust entering the machine, but the cleaning of the capsule edges is equally important. When sealing the sealing film, if there is coffee powder or dust adhering to the edges, it is very likely that the sealant of the sealing film will be misaligned, resulting in scrapped or leaking capsules. To solve this problem, we add vacuuming equipment during the packaging process to remove the coffee powder attached to the edge of the capsule and reduce the effect of particulate matter on the capsule seal.

4. Static Bars

There are a large number of metal parts inside the machine, their contact with the capsules and sealing film will generate a lot of static electricity, which will lead to the adhesion of dust and coffee powder, which will have an impact on the electrification components and equipment or the quality of coffee capsules, in order to avoid this situation to ensure efficient and stable production, we have added a static bar to the design of the machine, through nitrogen flushing, constantly scattering the static factor inside the machine.

5. air gun

Inside our standard coffee capsule packaging machine, it is equipped with an air gun. It is very helpful for cleaning the dust and losing coffee powder from the hopper and inside the machine.

6. Motor Drive

Most of the coffee capsule filling machines that customers can buy are pneumatic chains, which will constantly produce friction and leak gas, generating static electricity and dust. The long time friction with dust will reduce the life of the corresponding parts and will also affect the accuracy of the machine's operation. And the noise generated by pneumatic is also a problem that needs to be solved.

We use a motor-driven chain in order to solve all problems from the customer's point of view. The function of the motor is the same as that of the air motor, and the cost is higher, but the use of electric power reduces the generation of shadow. Moreover, the motor is smoother and reduces the friction between the chains, which prolongs the life of the machine and its parts and meets the demand for high-standard machines.

7. Two Seals

The seal needs to make the seal adhesive and capsule on the membranes of the edge contact, fully met the requirement of the temperature, the dust gets in the way of contact and transmission of the temperature, the seal before the dust cleaning is carried out by vacuum dust bag, effectively maintain a clean and tidy the edge of the capsule, in order to ensure the reliability of the seal, we joined the second seal, minimize the influence of the dust.

8. maintenance of machines

The addition of dust control measures to the coffee capsule packaging machine will help prevent the impact of powder on the production operation, but also requires the operator to follow the appropriate machine preventive maintenance plan, keeping the machine in the best condition can make the production work easier.

Many preventive maintenance tasks include cleaning and checking parts for residue or dust. Using the convenience of air guns, it is best to clean once a day, and it is also necessary to clean up after the replacement of hopper materials.

A brief introduction to the Rotary K cup Filling Machine from AFPAK to make you know every detail of the machine

1. A simple description of Rotary K cup Filling Machine are revealed below.

A Rotary k cup machine is a highly efficient machine for filling and sealing k cups. It is developed by engineers with over 10 years of experience in the coffee capsule and k cup business and it is manufactured to support small to medium-size businesses, featured with relatively low cost, high efficiency, and maneuverable operation, thus improving the production capacity to meet the increased demand from customer.

Compared to a linear type filling machine on which the K cups or capsules needed to be filled and sealed tends to move linearly, a rotary k cup filling machine has a round turntable moving circularly with k cups or any other kind of coffee capsules.

This simple difference brings a lot of benefits to better serve the small and medium-sized businesses, as the rotary k cup machine itself takes up less space for the installation.

That means within the same workshop of small and medium-sized businesses, more rotary k cup machines can be fitted.

Efficiency and production capacity are advanced and boosted greatly.

The turntable or, to be more precise the rotary table, is moving more stably to make sure the smooth process of filling and sealing, so to stop the coffee powder from spreading out of the k cups.

This feature also ensures the k cups are sealed with the lids on in a better way as the lids would be placed more tightly so to keep the coffee granules fresh and improve the shelf life of k cups.

The rotary k cup machine has the capacity to process from 40 and up to 100 k cups every minute.

K cups made of various types of raw materials could be sealed and filled by the rotary k cup machine, as long as they fit into the rotary table.

Besides different types of granules, liquid, drinks, beverages, yogurt, and powders such as tea granules, coffee powders or other types of liquid could be filled into the k cups by this rotary k cup machine.

2. This part shows the building of the rotary k cup machine, namely the structure

After years of rich experience with the AFPAK team, who has gained a deep understanding of the coffee capsules and k cups market through years of market research and key information shared by regular customers, AFPAK came up with the idea of providing rotary k cup filling machine.

Through multi-time of tests and strict quality control by the team, and by using the carefully selected raw material, the team managed to launch this rotary k cup machine.

And soon it became one of the most well-known coffee granule filling and sealing machines worldwide.

Stainless steel and aluminum alloy are applied to form the frame so as to reduce the weight of the machine meanwhile make it easier for cleaning.

The rotary k cup filling machine is equipped with a capsule dropper, cup or capsule sensor, lid sensor, nitrogen filling system, edge cleaning system, and more, with basic functions of cup dropping, filling cups, and sealing cups with lids.

Apart from those, by adapting the latest technology, it is possible to set how many cups are going to be filled and sealed by the machine within a certain time period which could be set as well by programming.

The rotary k cup machines were launched as a supplement to the linear k cup machine which has the advantages of small size and simple operation.

However, rotary k cup filling machines are relatively more efficient.

3. The main functions of the rotary k cup filling machine are presented.

For small and medium-sized businesses in the coffee granule filling and sealing business, it is strongly suggested to have the rotary k cup machines installed in their plants or workshops, not only because of the portability of the machine but also because of its relatively low cost and handiness.

A greater amount of k cups could be filled and sealed by the rotary k cup filling machine than by the hand-manipulated machine, indicating a better efficiency. It has a nice layout and design, small in size but relatively large in its capacity.

The launch of this rotary k cup machine aims to make production easier, free worker’s hands, improve productivity, gain higher accuracy in filling and sealing,render a easy job of cleaning, and enable the production versatile in terms of various type of k cup related products.

3.1 Servo motors are applied to enhance the accuracy of the filling and sealing process by the rotary k cup filling machine center.

The filling is carried out vertically driven by the servo motor.

Besides, automation of providing the granules greatly improves the precision of filling.

Furthermore, the efficiency of the sealing process is increased as the motor drive system ensures faster and steady sealing.

0-40 Celsius temperature can be set based on the requirement and under real conditions.

Lastly, thermal insulation products from Japan are applied to the rotary k cup filling machine to protect its parts as the processing produces a lot of heat, bringing negative effects on the processing and also causing certain issues such as damaging the parts of the machine.

3.2 The rotary k cup machine is equipped with a nitrogen flushing system to ensure a better shelf life of the products.

The freshness of the granules or liquid inside the k cups is kept longer when filled with nitrogen to make sure a great taste and high quality.

3.3 Moreover, smart sensors are adapted by rotary k cup filling machines to make the machine more intelligent, easier, and safer for operation.

If the sensor realizes that there are no lids on the rotary table, the filling and sealing process will be automatically stopped to prevent the machine from getting coffee granules scattered everywhere, which enables a simpler approach to cleaning.

3.4 Additionally, the rotary k cup machine could calculate the quantity of the k cups filled and sealed which is time-saving for the workers.

And surely, one could set English as the system language.

The machine can run for 24 hours for any business to produce a greater amount of products.

When the issue occurs, it will notify so the engineer knows where needs to be maintained.

4. AFPAK Highlighted Rotary K cup Filling Machines

AFPAK has a wide range of k cup filling sealing packaging and cartoning machines lines, of which the disc type machines are our best sellers.

After collecting years of customers trial feedback combined with the continuous upgrading of technology, we now have machines that are easy to use, superior in performance, and reliable in quality.

And now we recommend:

4.1 Super hot explosive model- RN1S Rotary K cup Filling Machine

This RN1S rotary k cup filling machine we can sell up to 20 units a month all over the world.

With its elegant design, complete functionality, and excellent performance, it will be your best production helper if you are a startup or a medium-sized company.

4.2 RN120 Rotary K cup Filling Machine

RN120 rotary K cup filling machine is an equipment that is more efficient and doubles production output.

It has the same performance and features as the RN1S but can produce up to 120 cups per minute.

Ideal for medium to large companies that need more precision and better performance in their coffee business

Conclusion

All in all, the purpose of launching the rotary k cup filling machine is for small to medium size business to grow their business and gain more customers and sales in a more efficient way.

The functions of the rotary k cup filling machine will be constantly enhanced and improved by the team of AFPAK to meet the ever-changing demands of customers.

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