Theegarten-Pactec prepares to unveil new lines for interpack

An innovative series of packaging machinery is set to be unveiled by German-based equipment specialist Theegarten-Pactec at this year’s interpack event in Düsseldorf, reports Neill Barston.

The business will be joining more than 2,800 companies from around the globe, with the confectionery, snacks and bakery segments strongly represented among the latest industry kit and systems being showcased.

For its part, Theegarten-Pactec will be returning to the key German event, which is staged every three years, at its traditional Düsseldorf Messe location between 7-13 May, offering a major cross-industry packaging and processing platform.

Significantly, as the company noted, for the first time at a joint stand with its partner Makrev (Hall 1, Stand B51), presenting its customised packaging machines for every type of product and requirement.

While Theegarten-Pactec is known for high-speed solutions for packaging small confectionery items in combination with a multitude of folding types, the company will be placing a particular focus on effective packaging in flow packs at interpack 2026.

Both new as well as evolved, proven systems will be on display. Manufacturers of chocolate, bars, snacks and functional foods will experience how they can benefit from maximum flexibility, automated lines and digitally networked machines from this innovation driver – customised, smart solutions for a wide variety of products, packaging materials and performance ranges.
FPC6: from the flow pack directly into the carton

With the FPC6, a new generation of machines which will be presented at interpack for the first time, Theegarten-Pactec is deliberately focusing not on ‘faster, higher, further’, but on stable efficiency.

The high-performance machine reliably packs chocolate bars, tablets and pralines into flow packs and is specifically aimed at manufacturers of chocolate, confectionery, muesli and protein bars, functional foods and snacks, as well as co-packers and contract packers. With the new machine, Theegarten-Pactec is also providing a single-source system that feeds flow-wrapped bars directly into the BLM cartoner.

Notably, as the company revealed, the FPC6 has been engineered for maximum user-friendliness: mechanical enhancements reduce complexity and, given the ongoing shortage of skilled workers, also support less experienced personnel in safe and reliable operation.

An improved display also simplifies troubleshooting: the machine alerts the operator to the location of the possible problem area. This allows the machine to be operated independently with high efficiency. The tool-free removal of machine parts also contributes to this: critical parts that are prone to contamination can be replaced without tools.

They are designed in line with the ‘poka-yoke’ principle (a Japanese method for preventing errors in production and work processes), i.e. installation errors are prevented from the outset because the components are designed in such a way that incorrect installation during format changes and/or cleaning is impossible. These include, for example, belt assemblies and belt guides.

Flexibility in sealing 
The FPC6’s sealing device has also been designed to reduce complexity. It is exceptionally user-friendly and enables fast, reliable and error-free format changes. The tool-free replacement of the cross-sealing unit is guided and largely automatic via the HMI (Human-Machine Interface) and can be carried out with a conventional manual pallet truck – special, and often expensive, transport devices are not required.

Furthermore, the machine not only processes a wide variety of product formats without major changeover effort, but can also master several types of sealing – cold sealing, heat sealing and separation seam welding for water-soluble films – thereby offering maximum flexibility in terms of packaging materials.

An integrated preheating section ensures that even sensitive materials such as paper or recyclable mono films can be processed reliably and with the highest possible efficiency and consistent quality. 

‘Flying Splice’ high-efficiency changes, reliable processes with web edge control
On average, the packaging material needs to be changed every 20 to 30 minutes during the packaging process, which is why the FPC6’s packaging material unwinding system has also been optimised.

In conjunction with the sealing device, the ‘Flying Splice’ takes over critical steps that previously required precise threading and gluing of the double-sided adhesive strip. A roll prepared with adhesive tape is simply placed on the machine; no further steps or special precautions are necessary. Correct application, alignment and feeding are all performed automatically.

Furthermore, roll changes can be carried out without reducing speed, even at packaging speeds of 150 m/min. The ‘Flying Splice’ feature increases both process reliability and system availability with minimal training requirements.
The FPC6’s packaging material web tracking control also allows the course of the film web to be adjusted directly on the HMI – for example, depending on the batch or when changing flavours. Old and new values are automatically stored in the recipe management system. Manual settings that were previously necessary are no longer required, and the original target value is retained.
Optimised product feed for a reduced footprint

The FPC6 excels with short feed paths, even in high-performance operation. Belt stages can be precisely calculated and reduced, which significantly decreases the installation area. Thanks to the optimised design, feed speeds of up to 100 m/min are now possible – significantly faster than the previous 70–80 m/min and without bottlenecks in the production line.

In addition, the system features a new, HMI-supported setting for film tension at the forming shaft. This enables operating personnel to adjust the tension of the film tube easily, without tools and without prior knowledge – a decisive advantage when packaging materials behave differently depending on the batch or due to environmental influences such as temperature and humidity. 

FPH5: Flow-wrapped pouches for entry-level applications
In addition, Theegarten-Pactec is presenting the modular FPH5 for the reliable packaging of preformed products in flow-wrapped pouches. The first machine manufactured in collaboration with partner Makrev in Turkey is designed for simple applications and achieves an output of 2,000 packaged products per minute.

With this machine, Theegarten-Pactec is strengthening its competitiveness in the entry-level segment. More advanced systems for chiclets, multi-piece packs or jelly products, as well as customised solutions, will continue to be developed and manufactured at the Dresden site.

CHS with ‘Smart Bunch’
Specially developed for the gentle packaging of chocolate products, the CHS offers exceptional flexibility: it enables quick changes between different folding types as well as rapid format changes – while ensuring high product protection thanks to its continuous operation.

First presented at interpack 2023, the CHS has become the company’s flagship product in just under three years. Since then, 15 machines have been installed on the market, and the system has been continuously optimised and expanded in terms of its functions.

Now Theegarten-Pactec is presenting an additional folding type, the ‘Smart Bunch’, in which the closure is made at the side. This expansion not only increases the flexibility of the machine, but it also reduces the consumption of packaging materials without compromising on efficiency.

BLM cartoner
Beyond the packaging of confectionery, Theegarten-Pactec also has some exciting innovations in store for interpack 2026. With the BHS, which was launched in March 2025 and is already in operation at several customer sites in Africa, the company is presenting an innovative high-performance machine for bouillon cubes that sets all-new speed standards

The line impressively demonstrates how up to 3,000 preformed tablets/min can be packed reliably. For cubes, 3,000 products/min are achieved for single packaging and 6,000 products/min for packaging in packs of two.

EK4: double twisted, efficiently packaged for 20 years
With the EK4, Theegarten-Pactec is showcasing the world’s fastest packaging machine for preformed products in double twist wrapping. This proven solution has been in use for over 20 years and is continuously being developed and adapted to customer requirements. It has recently been equipped with a latest-generation control system. Some 115 systems are already in use worldwide, with more on order. The EK4 achieves an output of 2,300 packaged products/min and excels in the efficient, yet gentle and reliable packaging of sweets and other preformed products.