Overall Solution for Four-side Sealing Packaging Machine

This solution is customized for the customer’s fully automatic four-side sealing packaging production requirements for sachet materials. It is applicable to various materials such as powders, granules, liquids and pastes, and widely used in food, daily chemical, pharmaceutical, agricultural and other industries. The equipment integrates fully automatic processes including automatic bag forming, photoelectric positioning, precise filling, four-side sealing, finished product cutting and fault self-inspection. It solves the common production pain points of traditional packaging such as complicated procedures, uneven sealing edges, large measurement errors, insufficient capacity and material waste, helping customers realize standardized, high-speed and intelligent packaging production suitable for mass production and refined quality control.

1. Customer Pain Points and Demand Analysis

1.1 Existing Production Pain Points

Insufficient Packaging Accuracy：Manual operation or old equipment leads to large material measurement errors, inconsistent finished product specifications and low yield rate, failing to meet industry quality inspection standards.
Unstable Sealing Quality：Four-side seals are prone to wrinkles, incomplete sealing, leakage and edge cracking with poor tightness, causing products to be damp, leaked and deteriorated and resulting in high after-sales loss.
Obvious Capacity Bottleneck：Single-station operation has low efficiency and cannot meet mass production orders. Excessive manual intervention leads to high labor cost and uncontrollable production rhythm.
Poor Compatibility：Traditional equipment has poor compatibility with packaging films and bag sizes. Product specification replacement requires complicated and time-consuming commissioning, resulting in insufficient flexible production capacity.
Low Intelligence Level：Lack of automatic deviation correction, fault early warning and data statistics functions. Problems such as film deviation, temperature abnormality and material jamming cannot be detected in time, leading to high downtime failure rate.

1.2 Core Requirements

Realize fully automatic integrated packaging to reduce manual intervention and lower labor and material loss costs.
Ensure flat, firm and standard-tight four-side seals without leakage or wrinkles, and consistent finished product appearance.
Meet specified capacity indicators, support stable and continuous mass production, and adapt to switching production of multi-specification products.
Compatible with mainstream packaging materials such as composite films and aluminum foil films for sachets of different sizes.
The equipment operates stably with easy operation and maintenance, and is equipped with intelligent self-inspection and safety protection functions to adapt to standardized workshop operation.

2. Overall Solution Design

2.1 Core Positioning of the Solution

Adopting the integrated technical architecture ofservo drive + multi-zone temperature control + precise photoelectric positioning + automatic tension deviation correction, it builds a high-speed, high-precision and high-stability fully automatic four-side sealing packaging production line. Customizable for single-row and multi-row models, the equipment can be flexibly adapted according to customer capacity, material characteristics, bag specifications and workshop conditions, realizing full automatic processes including film feeding, automatic bag forming, precise filling, four-side heat sealing, fixed-length cutting and finished product discharging, balancing production efficiency, product quality and operation convenience.

2.2 Core Configuration and Working Principle

The equipment consists of eight core modules: film feeding mechanism, tension deviation correction mechanism, photoelectric tracking mechanism, servo bag pulling and forming mechanism, multi-zone heat sealing mechanism, precise metering and filling mechanism, cutting mechanism and intelligent control system, which cooperate to complete standardized packaging operations.

Automatic Film Feeding & Tension Deviation Correction Module：Equipped with fully automatic film releasing mechanism and high-precision tension control system to adjust film tightness in real time. Matched with automatic deviation correction device, it eliminates film deviation and wrinkles to ensure regular bag forming and adapt to various flexible packaging films.
Photoelectric Positioning & Tracking Module：Equipped with high-precision color mark photoelectric sensor to accurately identify printed positioning points on packaging films, automatically correct bag length and sealing position, ensuring complete patterns and consistent sizes of each bag without offset or uneven bag length.
Servo Bag Forming Drive Module：Servo motor drives the bag pulling and forming mechanism. No mechanical parts replacement is required; bag length and width can be adjusted only via touch screen parameter setting, featuring high positioning accuracy, fast response and efficient model switching commissioning.
Multi-zone Independent Heat Sealing Module：Four independent temperature control zones (up, down, left, right) with PID intelligent constant temperature control accurately adjust heat sealing temperature, pressure and holding time according to film characteristics, solving uneven sealing problems of thick and thin composite films to achieve flat, firm and qualified seals without incomplete sealing or cracking.
Customized Filling & Metering Module：Equipped with corresponding metering structures for different materials: cup metering for granules, screw metering for powders, piston pump metering for liquids and pastes. Controllable metering accuracy greatly reduces material errors and meets filling demands of various materials.
Intelligent Control & Protection Module：Integrated control system of PLC and high-definition touch screen with simple and intuitive interface supports parameter storage, one-key start-stop and automatic operation. Functions including no bag-no feeding, abnormal shutdown, fault alarm, material jamming self-inspection and overload protection effectively reduce material waste and equipment loss.

2.3 Adaptable Parameters

Applicable Materials：Powders, granules, liquids, pastes and special-shaped small parts
Applicable Films：Various heat-sealable packaging films such as PE, PET, aluminum foil films and composite films
Bag Size：Standard width 20-180mm, length 20-200mm (extended and widened models available on request)
Packaging Speed：Single row: 30-80 bags/min; multi-row: 150-400 bags/min (adjustable according to materials and bag types)
Metering Accuracy：±1%-±5% (fine-tuned according to material forms; higher accuracy for granules and liquids)
Sealing Method：Four-side synchronous heat sealing with constant temperature and pressure shaping, flat and burr-free sealing edges
Control System：PLC intelligent control + touch screen operation, supporting parameter memory, fault self-inspection and data traceability

3. Core Advantages of the Solution

3.1 Stable Operation & Excellent Finished Product Quality

Adopting four-zone independent temperature control and precise pressure control system, matched with photoelectric color mark positioning and deviation correction technology, the equipment achieves uniform and firm heat sealing, thoroughly eliminating common quality problems such as incomplete sealing, leakage, wrinkles and bag deviation. The finished products feature high sealing tightness and appearance consistency with stable and controllable yield rate, fully meeting high-end industry quality inspection and batch delivery standards. The modular structure design, equipped with intelligent fault self-inspection and overload protection functions, monitors the equipment operation status in real time, greatly reducing the probability of material jamming and shutdown failures, and ensuring long-term stable continuous operation of the production line.

3.2 Full-automatic High-efficiency Production & Significant Cost Reduction

The complete equipment realizes full-process unmanned automatic operation including bag forming, filling, heat sealing, cutting and discharging without on-duty manual intervention, greatly reducing labor costs. Equipped with a high-speed servo transmission system, the packaging capacity can reach 100-150 bags per minute, far exceeding the production efficiency of traditional packaging equipment. The intelligent error-proof feeding design effectively avoids waste caused by empty bags, insufficient filling and defective products, greatly improves material utilization, and helps customers reduce production loss, increase overall capacity and realize lean production cost control.

3.3 Strong Flexible Adaptability & Wide Standard-compliant Application

The equipment supports digital parameter adjustment, enabling rapid product specification switching without mold replacement or mechanical disassembly, featuring efficient commissioning and flexible production for multi-category, small-batch and multi-batch production demands. It is compatible with various mainstream packaging materials such as film-coated paper, composite film, aluminum-plastic film, pure aluminum film and aluminized film, adapting to the production of multi-specification bags and different thickness packaging materials. The material contact parts are made of 304 stainless steel with dust-proof, anti-corrosion and easy-to-clean performance, complying with sanitary production specifications of food, pharmaceutical and other industries. With low noise and low energy consumption, it is suitable for various production scenarios including ordinary workshops and dust-free workshops.

4. Special Solutions for Common Problems

Targeted optimization solutions are provided for frequent faults in four-side sealing packaging to ensure long-term stable production:

Sealing Leakage / Unfirm Seal：Optimize multi-zone temperature control curve, fine-tune heat sealing temperature, pressure holding time and sealing pressure, clean carbon deposition on sealing knives, and adjust parameters according to film thickness to ensure sealing strength.

Film Deviation / Bag Wrinkles：Calibrate automatic deviation correction system and tension parameters, adjust gaps of carrier rollers and forming plates, stabilize film feeding rhythm and eliminate forming defects.

Excessive Metering Deviation：Calibrate the accuracy of metering mechanism, fine-tune feeding speed and filling time according to material fluidity, and calibrate metering benchmark regularly to ensure stable weighing.

Uneven Bag Length / Pattern Offset：Calibrate photoelectric sensor sensitivity, correct servo bag pulling parameters, lock color mark positioning benchmark to ensure consistent bag sizes and patterns.

5. Detailed Equipment Parameter Module

This chapter presents official standard technical parameters of the equipment. All indicators are verified based on actual machine configuration, which are accurate for equipment selection, technical benchmarking and project acceptance, with non-standard customization available on request.

No.	Item	Technical Indicators
1	Production Capacity	100-150 bags/min (actual capacity depends on product layout)
2	Maximum Bag Forming Width	Width: 225mm (length customizable within traction stroke range)
3	Traction Stroke Range	50-800mm (extended customization available)
4	Packaging Materials (Roll Inner Hole: Φ75)	1. Film-coated Paper：（0.03～0.1）×240×(Φ350)mm2. Composite Film：（0.03～0.1）×240×(Φ350)mm3. Aluminum-plastic Film：（0.03～0.1）×240×(Φ350)mm4. Pure Aluminum Film：（0.03～0.1）×240×(Φ350)mm5. Aluminized Film：（0.03～0.1）×240×(Φ350)mm
5	Packaging Material Thickness	0.3-12mm (subject to layout margin of plate area)
6	Heating Power	6kw
7	Servo Motor Power	1. Traction Servo Motor：1.5KW2. Cutting Servo Motor：0.75KW3. Feeding Servo Motor：0.75KW4. Material Releasing Motor：0.75KW5. Easy-tear Motor：0.4KW
8	Reciprocating Heat Sealing Servo Motor Power	1.5kw
9	Power Supply & Total Power	380V, Total Power: 11.5kw
10	Air Pump Parameters	0.6～0.8MpaCapacity ≥0.25m³/min (self-provided), Working Pressure: 0.6～0.8Mpa
11	Overall Dimension (L×W×H)	5465×765×1675mm (split transportation in the middle, including foot height)
12	Overall Weight	1250KGApprox. 1250KG

6. Solution Summary

Combined with customers’ production pain points and mass production requirements, this four-side sealing packaging machine solution realizes full-process automatic, precise and intelligent upgrading relying on mature servo transmission, intelligent temperature control and photoelectric positioning technologies. It effectively solves the problems of unstable quality, insufficient capacity, high loss and poor compatibility in traditional production. Featuring high efficiency, stability, flexibility and economy, it comprehensively improves customers’ standardized packaging production level, reduces overall production costs and helps enterprises improve quality, increase efficiency and achieve large-scale mass production.