Sacchettini Packaging Solution
I.Overview
1.1 Background
The customer has already established a complete production line for frozen Sacchettini, covering raw material processing, forming, cooking, and individual quick freezing (IQF). The current focus is on the end-of-line packaging process—automatically packaging the frozen Sacchettini into pouches with high efficiency and consistent quality.
The objective is to achieve stable, reliable, and visually appealing packaging while increasing production capacity and ensuring consistent product presentation to meet market demands.
1.2 Objectives
This solution is designed to provide a highly efficient, flexible, and intelligent packaging system that automates the entire process from the IQF stage to finished pouch packaging.
By integrating conveying, weighing, and bagging into a seamless production line, the solution will:
- Ensure product quality throughout the packaging process.
- Deliver accurate and consistent weighing and filling.
- Improve overall production efficiency.
- Reduce labor dependency and operating costs.
1.3 Product Characteristics
Product: Frozen Sacchettini (Italian stuffed pasta)
Characteristics:
- Small individual pieces
- Prone to generating crumbs during handling
Packaging Requirements:
- Net Weight: 250g per pouch
- Pouch Type: Stand-up Pouch (Doypack)
II.Solution Design
The packaging solution consists of five core modules: Front-end Interface Integration, Product Elevating & Conveying, Weighing & Dosing, Packaging Unit, and Finished Product Discharge.
Each module has been carefully designed based on the customer’s production process, site conditions, and product characteristics to ensure stable operation, food safety, ease of cleaning, and future scalability.
2.1 Front-end Interface Integration
○ Product discharge dimensions: 1,000 mm (W) × 920 mm (H).
○ The product drop height is controlled within 400 mm to minimize product impact and preserve the integrity and appearance of the frozen Sacchettini.
○ A large-capacity collection hopper (internal width ≥ 1,000 mm) is designed to receive products evenly from the upstream production line, ensuring continuous material flow while reducing product damage caused by concentrated discharge.
2.2 Product Elevating & Conveying
Large Incline Elevator：The Large incline elevator transfers the frozen Sacchettini from the collection hopper to the multihead weigher.
- Food-grade conveyor belt designed for low-temperature applications, featuring excellent anti-stick performance and easy cleaning.
- Compact structure with quick-disassembly design for convenient maintenance and hygienic operation.
2.3 Weighing & Dosing
○ 10-Head 2.5 L Dimple Plate Multihead Weigher
● Waterproof and moisture-resistant design, ideal for frozen products with surface frost.
● High weighing accuracy with a tolerance of ±1%.
● Dimple plate hoppers improve product flow and reduce sticking, ensuring smooth and consistent weighing performance.
○ Maintenance Platform：An ergonomic maintenance platform provides safe and convenient access for inspection and servicing of the multihead weigher.
2.4 Packaging Unit
Vertical Form Fill Seal Machine (VFFS)
- IP65-rated design suitable for high-humidity food processing environments.
- Optional gas flushing system (nitrogen or mixed gas) to help protect the product from compression during transportation and handling.
- Integrated Thermal Transfer Overprinter (TTO) for real-time printing of production dates, batch numbers, barcodes, and QR codes.
2.5 Finished Product Discharge
○ Finished Product Conveyor: Smoothly transfers packaged products to the next processing stage, such as inspection, case packing, or palletizing.
○ Rotary Accumulation Table: Collects finished pouches for temporary accumulation and manual handling, improving operational efficiency.
III.Features & Benefits
○ High Efficiency
The solution delivers a fully automated packaging process, from frozen Sacchettini discharge at the upstream production line to finished pouch output.
By combining the Large Incline Elevator with a high-speed multihead weigher, the system ensures continuous product conveying and fast, accurate weighing. The integrated Vertical Form Fill Seal (VFFS) machine enables high-speed bag forming, filling, sealing, and coding within a single automated process.
The automated solution significantly reduces manual intervention while maintaining product integrity and achieving high production efficiency, enabling the customer to meet growing market demand with stable and reliable output.
○ Superior Hygiene
All product-contact components are manufactured from food-grade stainless steel and certified food-safe materials, providing excellent corrosion resistance and easy cleaning.
Key equipment, including the multihead weigher and the VFFS machine, features a water-resistant design, making the system suitable for washdown procedures and high-humidity food processing environments.
○ Excellent Scalability
The solution is designed with reserved interfaces for seamless integration with future downstream equipment, allowing customers to expand production capacity as their business grows.
Optional downstream equipment includes:
- Metal Detector for foreign object inspection.
- Checkweigher for automatic weight verification.
- Automatic Case Packer for fully automated carton loading.
- Palletizing Robot to support unmanned end-of-line packaging operations.
The system control platform also supports data acquisition and remote monitoring, enabling easy integration with ERP and MES systems to facilitate smart factory implementation.
IV.Conclusion
This solution is specifically designed to meet the automated packaging requirements for frozen Sacchettini while integrating seamlessly with the customer’s existing production line. By combining high efficiency, operational reliability, and compliance with international food processing standards, it provides a complete and dependable packaging solution for modern food manufacturers.
The solution not only improves production efficiency and packaging consistency but also reduces labor requirements and minimizes quality risks, helping the customer strengthen its competitive position in an increasingly demanding market.
We are confident that this solution will enable the customer to achieve a more standardized, efficient, and sustainable production process while establishing a solid foundation for future product diversification and business expansion.
Resure is committed to supporting the success of every solution with professional engineering design, reliable equipment manufacturing, and comprehensive after-sales service, ensuring smooth project implementation and long-term operational performance.
