Optimising a liquid stick pack machine for viscous products requires a deeper technical approach than standard liquid packaging. Products such as honey, syrups, gels or cosmetic creams behave differently during forming, filling and sealing due to their high resistance to flow and tendency to adhere to surfaces.
These characteristics directly affect dosing accuracy, seal quality and machine efficiency. Understanding how viscosity interacts with machine configuration is essential to achieve stable performance and consistent pack quality.
Viscous liquids introduce specific challenges in stick pack applications. Their slow flow rate, internal friction and surface adhesion increase the risk of irregular dosing, product residue in critical areas and air entrapment inside the pack.
If a liquid stick pack machine is not properly configured, these factors can lead to higher rejection rates, hygiene issues and reduced output.
Viscosity has a direct impact on dosing precision and cycle stability. Thick products require higher and more consistent pressure to achieve accurate fill volumes, especially at higher speeds.
In a liquid stick pack machine, the dosing system must be capable of handling these flow characteristics without pulsation or delay. Inadequate control often results in underfilling, overfilling or inconsistent stick weights, affecting both efficiency and compliance.
Seal integrity is particularly sensitive when packaging viscous products. Sticky formulations can contaminate the seal area if flow cut off is not clean or if sealing parameters are not properly adjusted.
This increases the risk of weak seals and compromises hygiene. For food, pharmaceutical or cosmetic applications, maintaining clean sealing zones and enabling effective cleaning is a critical requirement for any liquid stick pack machine.
To ensure reliable performance with viscous liquids, several configuration elements must be carefully evaluated. Optimisation should consider the complete interaction between product behaviour, machine mechanics and packaging materials.
Film selection plays a key role in reducing adhesion and ensuring seal consistency. Multilayer films with suitable barrier properties and surface treatments help minimise product migration into the seal area.
Sealing temperature, pressure and dwell time must be fine tuned to the specific film and product combination. In a liquid stick pack machine, excessive heat can worsen seal contamination, while insufficient heat can cause leaks or poor seal strength.
Precise calibration is essential to maintain process stability when handling viscous products. Synchronisation between dosing, forming and sealing stages ensures repeatable performance across long production runs.
Regular fine tuning helps reduce variability, stabilise fill weights and limit product waste, especially when viscosity fluctuates due to temperature or formulation changes.
Improving productivity with viscous liquids is possible when both product management and machine setup are aligned. Conditioning the product to maintain a consistent temperature can significantly improve flow behaviour and dosing repeatability.
In a liquid stick pack machine, preventive cleaning strategies and controlled start up procedures also contribute to higher overall efficiency by reducing unplanned stops.
Machine design has a direct impact on uptime. Systems with modular components, smooth surfaces and easy access points simplify cleaning and maintenance operations.
A liquid stick pack machine designed for quick intervention allows operators to reduce downtime, especially when frequent cleaning is required due to sticky or highly viscous products.
One common mistake is overheating the sealing area in an attempt to compensate for seal contamination. This often worsens the problem instead of solving it.
Other frequent issues include selecting an unsuitable dosing system, using films that are not compatible with viscous formulations or neglecting preventive maintenance. Over time, these errors reduce performance and increase operating costs.
Maximising the performance of a liquid stick pack machine when packaging viscous products requires a combination of technical knowledge, correct configuration and proactive maintenance.
By understanding how viscosity affects each stage of the packaging process, manufacturers can achieve stable production, improved productivity and long term reliability, even with demanding liquid formulations.