Flexible implementation of hygienic pouch packaging

A growing requirement in the packaging industry is the ability to run a broad range of package sizes and products on a single machine. Traditional chain-driven systems with fixed speeds and formats can’t keep up. When Bartelt Packaging sought a technology partner to close the gap, they found a match in Beckhoff and the mechatronic XTS system that enables changeovers at the touch of a button.

From powders and snacks to cheeses and consumer goods, today’s pouching operations demand equipment that can shift quickly, maintain consistent seal quality, and meet increasingly strict hygienic standards, often within a shrinking footprint. Headquartered in Sarasota, Florida, Bartelt Packaging started in 1941 as a machine shop in Rockford, Illinois. Seven years later, the company would make their mark on the packaging industry by producing what the company says is the world's first horizontal form, fill, and seal (HFFS) pouching machine. Today, as part of the renowned ProMach family of processing and packaging brands, Bartelt continues to deliver best-in-class pouching and cartoning solutions across a wide range of industries. Nearly every grocery store aisle in the U.S. displays packaging produced on their equipment.

Stress test for packaging’s best

However, increasing hygiene and performance demands in food packaging, where a customer application requiring high-level sanitation exposed the limitations of previously used track and control systems in washdown environments prompted Bartelt to explore alternative technologies and ultimately partner with Beckhoff.

Bartelt conducted extensive in-house testing of the stainless steel, IP69K-rated XTS Hygienic. “We beat up that demo system with days of continuous testing, including the addition of weights to each mover as a carrier to simulate maximum product weight,” says Tom Tomac, Vice President and General Manager, at Bartelt. “We put everything on it that we possibly could and put the XTS through its paces. We provided Beckhoff our detailed feedback and their dedicated engineers reworked and refined the solution for Bartelt and shipped another XTS Hygienic that took all the team’s testing feedback into account. More testing ensued, which we upped to another level with sticky, sugary gummy bears and more, but the new and improved system could not be beat.”

Mechatronic transport system changes the rules

The Bartelt MAG-B compact, MAG-L linear, and MAG-R rotary HFFS packaging machines are designed for a wide range of flexible packaging applications that demand high throughput, adaptability, and efficient use of space – capabilities made possible by the XTS or XTS Hygienic technology at the core of each system. With pitchless and wireless movers, which are controlled independently of each other by magnetic fields, the XTS enables seamless transitions between bag sizes and filling processes while maintaining maximum throughput. Linear motion based on electromagnetic propulsion provides smooth, accurate transport along a predefined path, ensuring precise and consistent motion control and product handling.

The MAG Series platforms can be configured in straight-line, rotary, or dual-lane layouts. The machines are designed for maximum packaging flexibility, handling a wide range of pouch sizes all on one platform with minimal changeovers. Each configuration supports both rollstock and/or pre-made pouches. By accommodating numerous pouch sizes and filling configurations within a single machine, the series offers a distinct advantage as product variety increases and batch sizes grow smaller in high-mix production.

The first iteration to reach the market was the MAG-L (Linear), which provides an in-line process flow layout, filling pouches along the machine’s length at speeds up to 150 pouches per minute. The XTS Hygienic-equipped MAG-B (Back) fills pouches on both the front and back of the machine to maintain the same output as the MAG-L but in a more compact design. The IP69K-rated machine offers full washdown capability as required in certain food applications. Meanwhile, the smallest iteration, the MAG-R (Rotary), utilizes the XTS in a rotary process to optimize floor space while delivering high production speeds. Many of Bartelt’s machine types are optionally available in the cleaning-friendly XTS Hygienic.

Built to run. Built to adapt.

In an industry characterized by high production volumes and tight margins, uptime is critical. Rapid changeovers and minimal cleaning time are essential as CPG manufacturers cannot afford extended downtime between products or formats. This is where the XTS-based series shines by providing digitally-controlled machine adjustments for fast and repeatable format changes. It supports higher speeds, variable timing between stations, and advanced pouch handling, including on-the-fly clamping, controlled shaking for product settling, optimized nitrogen filling, and scalable operation from simplex to triplex pouch indexing.

Unlike traditional mechanically indexed machines with fixed pitch and limited adaptability, the MAG Series machines’ use of XTS allows pouch indexing to be adjusted dynamically based on the product being run.

This higher level of automation further reduces reliance on increasingly scarce skilled labor. Automated repositioning of axes and tooling streamlines setup, while an integrated, in-house-designed auto-splicer, semi-automatic zipper splicer, and unwinder enable continuous operation during film roll changes. This design maximizes the effective use of film roll down to the core and reduces floor space by eliminating the need for third-party equipment.

Automation, motion control, and networking in one package

Beckhoff PC-based control hardware and software form the backbone of the new packaging machines, managing all aspects of automation and motion control. This tightly integrated control platform delivers impressive gains in performance, usability, and reliability.

From a development standpoint, Bartelt engineers point to Beckhoff’s TwinCAT software as a key differentiator. Chris Conley, Electrical Engineering Manager at Bartelt, affirms, “I really like their programming software – it is intuitive to use, simplifies programming and saves me engineering time.” TwinCAT provides a straightforward programming environment with built-in XTS track simulation and ‘Open from Source’ functionality, allowing code to be verified, updated, and debugged directly on the machine with confidence. The ability to run applications through a remote Windows connection to the controller further streamlines commissioning and support.

Control and computing tasks for the machines are handled by the ultra-compact C6032 Industrial PC, which provides significant processing power while occupying minimal cabinet space. The whole system is tied together by high-speed EtherCAT communication, enabling real-time motion control and I/O performance, automatic device recognition, along with rapid configuration and commissioning.

Built for tomorrow

Looking ahead, Bartelt sees packaging industry pressures on machine builders only accelerating: higher throughput, greater product variety, tighter quality expectations, and added features. Meeting these demands will require automation platforms that are inherently flexible. By incorporating XTS and PC-based control technology, the MAG Series was designed with exactly that future in mind, with adaptability and long-term scalability built into the platform from day one.