FAQ: packaging machine questions answered

Questions we hear most often.

From choosing the right machine to international service: here you will find answers to the most important questions about VARIOVAC.

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General Thermoforming packaging machines Tray sealers Medical Acceptance & service

Which packaging machine is right for my requirements?

That depends on your product, packaging method, format, material, output and the production space available. For smaller, compact configurations, the Maximus RE or Optimus are good options; for higher output and more extensive equipment, the Primus or Primus MP. For pre-formed trays, VARIOVAC offers the semi-automatic Rotarius tray sealer and the fully automatic Linus tray sealer.

What information does VARIOVAC need for an initial machine selection?

Above all, VARIOVAC needs your product dimensions and weight, the required capacity (packs/min or kg/h) and the floor space available. The pack format and packaging method you have in mind should also be discussed right at the start. Please also list any existing or planned infeed, dosing and downstream systems.

Is a thermoforming packaging machine or a tray sealer better suited to my application?

A thermoforming packaging machine heats and forms the bottom film directly in the machine. This gives you great freedom in format, pack depth and packaging method. A tray sealer seals pre-formed trays with a top film and suits production concepts built around fixed tray formats and the product presentation that goes with them. Which solution fits better depends on your output, the range of formats and the packaging material.

Does VARIOVAC offer standard machines or customised solutions?

VARIOVAC is consistently customer-focused. That means the machines are flexibly adapted to your product and your needs. In addition, the Optimus SE/SEL, for example, comes with a pre-configured specification for standardised applications and particularly short delivery times.

What pack formats can VARIOVAC machines handle?

The portfolio ranges from compact standard formats up to index lengths of 1,200 mm and pack depths of 195 mm on the Primus MP. Depending on the model, film widths of up to 720 mm are possible. The values for your specific configuration need to be checked together with VARIOVAC.

What packaging output can a VARIOVAC machine achieve?

Depending on the model, the Maximus RE achieves up to six cycles per minute, the Optimus up to 13 and the Primus up to 20. The Primus MP reaches up to 25 cycles per minute. The actual number of packs per minute results from the cycle rate and the format, and depends on the application.

Can several products and formats be run on one machine?

Yes, as long as the formats are within the machine's technical limits. Stored programmes and quick-change systems make recurring product and format changes easier.

Can I keep using my existing films, trays or pack formats?

This is checked on the basis of dimensions, material, film thickness, formability and sealability. VARIOVAC also offers matched rigid, flexible, skin, shrink, cook-in and lidding films as well as a range of trays and bags.

Which packaging methods are possible?

Depending on the model, sealing, vacuum, MAP (modified atmosphere packaging), skin, steam and shrink are possible. The Primus MP also supports multi-layer packaging (MLP).

Can VARIOVAC integrate existing line components?

Depending on the project, the machines can be combined with infeed systems, filling and dosing systems, labellers, printing systems and downstream inspection and conveying systems. To do this, VARIOVAC checks the output, pack transfer and interfaces of the existing components.

Does VARIOVAC also offer solutions for the entire packaging process?

Alongside packaging machines, the portfolio includes the Variolabel labeller, the Variotrack line converger, filling and dosing systems, and equipment for leak testing and gas analysis. This makes it possible to plan fully coordinated line concepts. The exact scope of supply is defined for each project.

Which utility connections are required?

Depending on the model, the machines need compressed air at a minimum of 6 bar and a suitable power supply. The Optimus, Primus and the MP models have integrated cooling concepts with no ongoing water consumption. Binding connection and consumption values are only available once the final specification is fixed.

Can a VARIOVAC machine be extended later?

Many machines have a modular design and can be prepared for future requirements as early as the project planning stage. Whether a specific extension or retrofit is possible depends on the base machine, frame length, control system and existing equipment.

How do the Maximus RE, Optimus and Primus differ?

The Maximus RE is a compact machine for smaller-scale production, with a packaging output of up to six cycles per minute. The Optimus offers more film widths, formats and packaging methods at up to 13 cycles per minute. The Primus is designed for larger formats, more extensive lines and outputs of up to 20 cycles per minute.

Which thermoforming packaging machine is best when production space is limited?

With its integrated control cabinet and a footprint of 1.7 m², the Maximus RE is particularly space-saving. The Optimus starts at a frame length of 2.5 m and, while still compact, offers more format and process options than the Maximus RE.

Which thermoforming packaging machine suits skin products with high product protrusion?

The Optimus EasySkin is designed specifically for premium skin applications. Its High-Dome system handles products with a protrusion of up to 55 mm. The machine achieves up to six cycles per minute.

Which machine suits particularly large or deep packs?

For pack depths of up to 135 mm and film widths of up to 560 mm, the Primus is the right choice. For anything beyond that, the Primus MP offers pack depths of up to 195 mm and considerably longer index lengths.

Can rigid and flexible films be run on the same machine?

VARIOVAC machines can be equipped to run both types of film on the same machine.

Which types of film can VARIOVAC machines process?

VARIOVAC machines can process PE/PA, APET, PP and Tyvek, among others.

How quickly can formats be changed?

Quick-change systems for tool components and stored programmes considerably reduce the effort involved in recurring format changes. The actual changeover time depends on which tools, cutting systems, pack guides and films need to be swapped.

How is the actual packaging output for my application determined?

The real-world output is determined on the basis of the packaging method, format, evacuation and gas flushing times, and upstream and downstream processes.

Can a VARIOVAC thermoforming packaging machine combine several applications?

Yes. For example, vacuum, MAP and skin applications can be run on the same machine. Possible combinations are subject to a technical check.

Are VARIOVAC machines suitable for a fully automated process?

Yes, for example with automatic infeed or robotics.

How do the Rotarius, Linus 650 and Linus 1100 differ?

The Rotarius is a semi-automatic tray sealer with a rotary table and dual-tool system. The Linus 650 and Linus 1100 are fully automatic inline machines. The Linus 650 achieves up to 15 cycles, or around 60 trays, per minute. The Linus 1100 is designed for medium to high output and flexible format changes.

What tray depths and product protrusions can the Rotarius handle?

The Rotarius handles trays up to 100 mm deep. A product protrusion of up to 25 mm is possible. For skin applications, the specified tray depth is up to 40 mm.

Can I use my existing standard trays?

That depends on the tray dimensions, the material, the flange geometry and the top film. Based on this information, VARIOVAC checks whether a suitable tool can be built.

Can MAP and skin packs be produced on the same machine?

Yes. A tray sealer can handle both MAP and skin applications on the same machine. Which combinations are possible in each case is subject to a technical check.

Which systems can be connected to a Linus tray sealer?

All VARIOVAC system extensions are available for the Linus 1100, for example as a line with tray denester, labeller, printer and filling system. The Linus 650 can also be combined with additional systems such as a tray denester, filling station, labeller or pick-and-place robot. The specific line configuration is tailored to your product and the output you need.

When is the Optimus MedicalLine the right choice, and when the Primus MedicalLine?

The Optimus MedicalLine is the more compact solution for smaller production areas, variable pack formats and outputs of up to 12 cycles per minute. The Primus MedicalLine is designed for larger formats, complex production requirements and outputs of up to 25 cycles per minute.

What format ranges do the MedicalLine machines cover?

The Optimus MedicalLine offers index lengths from 150 to 600 mm and a pack depth of up to 125 mm, and processes bottom films up to 550 µm. The Primus MedicalLine covers larger ranges, with index lengths of up to 1,200 mm, pack depths of up to 190 mm and, likewise, film thicknesses of up to 550 µm.

Are the machines suitable for cleanroom applications?

Packaging sterile medical goods demands the highest standards of cleanliness and hygiene. VARIOVAC MedicalLine thermoforming packaging machines are designed specifically for cleanroom use and feature numerous design details that minimise sources of particles and make cleaning easy. Standard equipment includes hygienic design to minimise particles, suitability for cleanroom classes to ISO 14644, easy-to-clean materials, sloped surfaces, rounded edges and an open design for fast access. Additional equipment options include an IP65 version, an external control cabinet to reduce particle load, central process exhaust ducting, silencers with an integrated particle separator and compressed air filters (e.g. sterile air filters).

How is consistent seal quality achieved?

With VARIOVAC's proprietary Rapid Air System. This advanced system ensures precise forming of the pack and consistent, secure seals every time, even with demanding or critical materials.

What qualification documentation does VARIOVAC provide?

Optional documentation packages give you all the documents you need to qualify your VARIOVAC MedicalLine machine in line with the standards and to demonstrate its suitability for use in regulated production environments. Each set of documentation is tailored to your machine and demonstrates compliance with the relevant requirements of standards and regulations such as ISO 11607, EN 868, the MDR (EU 2017/745) and the GMP guidelines. For validated use in the medical sector, VARIOVAC supplies standards-compliant documents: DQ (design qualification), IQ (installation qualification, proof of correct installation), OQ (operational qualification, proof of function to specification), PQ (performance qualification, proof of performance under production conditions), FAT (factory acceptance test, acceptance report before delivery) and SAT (site acceptance test, acceptance report at the place of use). This gives you complete, audit-ready and easily accessible information for smooth qualification, successful audits and long-term compliance.

Are VARIOVAC MedicalLine machines designed for the sterile barrier system in sterile medical packaging?

Yes. VARIOVAC MedicalLine thermoforming packaging machines are specifically designed to produce the sterile barrier system in a reproducible, validatable and user-friendly way.

Can the machines process Tyvek?

Yes. VARIOVAC machines process Tyvek with high seal quality.

What marking and labelling solutions does VARIOVAC offer for medical packaging?

VARIOVAC machines can be combined with proven printing and labelling technologies, including thermal transfer, laser, inkjet, flexographic printing and hot stamping. These systems are used depending on the product and can also be combined with one another. VARIOVAC's in-house labelling units can also be integrated flexibly into the packaging process. In this way, the solutions help to ensure traceability and product safety along the entire supply chain. The result is a validatable packaging process that reliably brings together functionality, patient safety and regulatory requirements, and gives optimum support to the sterile barrier system (SBS) of your products.

What is the difference between FAT and SAT?

In the factory acceptance test (FAT), the machine is tested at the VARIOVAC site in Zarrentin before delivery. In the site acceptance test (SAT), acceptance takes place at your premises, with a particular focus on checking function and integration in the actual production environment.

Can machines be demonstrated online?

With VARIOVAC Studios, machines can be presented to you live via video conference.

What training does VARIOVAC offer?

Training is tailored to the machine and to the participants' area of responsibility and level of knowledge. Possible content includes operation, fault diagnosis, maintenance and how to fix common faults. On request, technical training is also available online via video conference.

What maintenance services does VARIOVAC offer?

VARIOVAC offers regular maintenance and maintenance agreements. With a maintenance agreement, VARIOVAC takes care of coordinating the scheduled maintenance appointments.

How is the supply of spare parts organised?

Genuine spare parts are supplied from the central logistics centre. Spare parts packages can also be put together to match your specific machine.

Is international service available?

VARIOVAC works with a worldwide sales and service network in 82 countries. Depending on your location, support is provided by VARIOVAC or the responsible service partner.

How can packs be checked for leaks and protective gas content?

The Rondo and Quarree leak testers check MAP packs for leaks non-destructively in a water bath. For gas analysis, VARIOVAC offers systems ranging from spot-check measurement to inline real-time monitoring. Inline systems can stop the packaging process automatically if deviations occur.

Who should I contact if my machine develops a fault?

VARIOVAC technical support is available Monday to Saturday by hotline, WhatsApp and email: phone +49 38851 823-900, email service@variovac.de. Service hours: Mon to Fri, 6:00 am - 7:00 pm; Sat, 7:00 am - 7:00 pm.

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