Automated Packaging Systems for Confectionery Production

ULMA Packaging will present updated flow-pack and vertical packaging systems for chocolate and confectionery products at ProSweets 2026 (1–4 February 2026, Cologne, Germany), focusing on shelf-life control, material efficiency, and automated packaging lines.

Packaging requirements in confectionery manufacturing
Confectionery and snack producers operate under constraints linked to moisture sensitivity, oxygen exposure, mechanical stress on heavy products, and increasing pressure to reduce packaging material use. At the same time, production lines must support high throughput, format flexibility, and digital integration with factory systems. The technologies shown by ULMA Packaging address these constraints through sealing technology, material handling capability, and machine-level digitisation.

Hermetic flow-pack solution for 5 kg chocolate blocks
One solution demonstrated is a horizontal flow-pack system designed for large chocolate blocks up to 5 kg. The machine supports technical films up to 100 microns thick, including aluminium-layer structures, to provide mechanical resistance during transport and storage.

Hermetic sealing is achieved using long-dwell Box Motion sealing, which increases sealing time under pressure and temperature control. This mechanism reduces the risk of seal defects when processing barrier films and enables protection against moisture, oxygen, and light. Under controlled storage conditions, this packaging approach supports shelf lives of up to 24 months without altering product texture or flavour. Format changeovers are designed to be performed with limited downtime, allowing adaptation to different block dimensions within the same line. The system is intended for integration into automated packaging and end-of-line configurations.

Vertical packaging for formed doypack-style formats
ULMA also presents a vertical form-fill-seal solution capable of producing pillow-pack and doypack-style formats directly from rollstock. A patented cutting mechanism enables shaped packages comparable in appearance to pre-formed pouches while avoiding their handling and purchasing costs.

The system is specified for production speeds of up to 80 packs per minute, depending on product and film type. By forming the package in-line, manufacturers can reduce packaging material costs by up to 50% compared with pre-formed doypacks. The cutting process eliminates approximately 4 mm of excess film per pack, lowering overall material consumption and associated waste.

Digital integration and process monitoring
Both technologies are equipped with a 10-inch colour touchscreen operated via an industrial PC. The interface supports connection to MES, ERP, and SCADA environments, enabling production data exchange, OEE analysis, and optional monitoring of energy and material consumption. These functions are intended to support process transparency, maintenance planning, and efficiency optimisation in confectionery packaging operations.

ULMA Packaging will exhibit these systems in Hall 10.1, Stand F008, with application focus on chocolate, confectionery, and snack manufacturing lines requiring high barrier performance, cost-controlled packaging, and digital process control.

www.ulmapackaging.com