The VARIOVAC glossary. Every packaging technology term, clearly explained.

Add-ons for customising and automating packaging machines. Examples include filling and dosing systems, labellers, coding and printing systems as well as pack convergers and stackers such as the Variotrack and Variostack. The Variocart and Variolift are available for handling tools and film rolls.

The basic tool set consists of the forming tool and the sealing tool. Both tools consist of an upper and a lower part and are exchanged when the format changes. The Variocart tool trolley is available for transporting and storing the tools.

Unwinds the bottom film (carrier film) and feeds it evenly into the machine. From there, the film runs into the forming station, where the cavities are formed. Depending on the machine, bottom films of up to 550 µm (Primus) or up to 1,000 µm (Optimus MP, Primus MP) can be used. The Variolift lifting aid is available for changing film rolls.

Packaging machine that evacuates and seals products in bags inside a closed chamber. VARIOVAC offers tabletop, single-chamber and double-chamber machines.

Additional equipment that can be combined with a main machine. These include labellers such as the Variolabel RE, coding and printing systems, the Variotrack line converger, leak testers, gas mixing systems as well as the Variocart and Variolift. Each product page lists which products are compatible with the machine.

Compressed air supply needed to run the machine (in bar). On VARIOVAC thermoforming packaging machines, compressed air is also used to form the bottom film: the RAPID AIR SYSTEM forms the cavities with compressed air, often without pre-heating.

System that cuts through the film web across the direction of travel. Depending on the pack, different knives are used, such as a guillotine, a die cutter or crush cutters. Together with longitudinal cutting, it separates the sealed packs before they leave the machine on the discharge conveyor.

Vacuum packaging machines for professional applications with high packaging volumes. Two separate vacuum chambers make it possible to prepare in one chamber while packing in the other. Up to 10 programmes, double-seam sealing as standard and height-adjustable insert plates are part of the equipment.

Sealing system on chamber machines that closes the bag with two seams. It is standard on VARIOVAC single-chamber and double-chamber machines, with cut-off or wide sealing available as options.

Maximum depth to which the film can be drawn into the cavity during thermoforming. It limits the height of products that fit into the cavity. The Maximus RE reaches a draw depth of up to 90 mm, while larger machines such as the Primus MP form packs up to 195 mm deep.

Simplified skin packaging process. It is implemented on the Optimus EasySkin, which works with chain-guided top film pre-heating and packs products that protrude up to 55 mm. Typical applications are high-quality meat products and fish.

Method in which the air is drawn out through nozzles and protective gas can be added if required. It is one of the evacuation methods used on thermoforming packaging machines, the alternative being a narrow top film. Because protective gas can be added, it is also suitable for MAP packs.

The process of drawing the air out of the pack to create a vacuum. It is the basis of vacuum packaging and, with MAP, takes place before the protective gas is added. On thermoforming packaging machines it is done by edge evacuation or with a narrow top film, while tabletop chamber machines reach up to 99.8 % vacuum.

Module that extends the machine frame. Extension modules increase the frame length beyond that of the base machine. For the Optimus MP and the Optimus MedicalLine, modules from 1.0 to 3.5 m in length are available, with the base machine measuring 2.5 to 5.5 m in each case.

Acceptance of the machine at VARIOVAC in Zarrentin. The machine is inspected in person in the showroom before delivery. On request, the factory acceptance test can also be carried out digitally via VARIOVAC Studios, which saves travel.

Filling and dosing systems dose and fill liquid, paste-like or chunky products precisely and ensure consistent packaging results. They fill quantities of 50 to 5,000 ml, cold or hot, for example soups, sauces, stews, goulash or purées. They can be combined with the Maximus RE, Optimus, Primus and the Linus tray sealers, among others.

Width of packaging film the machine can process. It limits how wide the pack format can be and varies from machine to machine. At VARIOVAC, it is 420 mm on the Maximus RE, 320 to 460 mm on the Optimus, 320 to 560 mm on the Primus, up to 660 mm on the Primus MP and up to 720 mm on the Primus MedicalLine.

Packaging solutions for food. At VARIOVAC, this area covers ten food categories, from meat and sausage, dairy products and baked goods to hot products and alternative proteins. Depending on the product, packaging methods such as vacuum, MAP, skin, shrink, steam or MLP are used.

Subdivision for the different pack formats. At VARIOVAC, the pack format is given using the pattern 'lanes.rows'; PG 2.3, for example, stands for 6 packs per cycle.

Machine station where the bottom film is formed into the shape of the pack. In the forming tool, the film is heated and then formed into the cavities either by vacuum (Maximus RE) or with compressed air using the RAPID AIR SYSTEM. The cavities then move on to the loading area, where the product is placed in them.

The forming tool consists of an upper and a lower part. The film is heated in the upper part and then formed in the lower part. At VARIOVAC, forming is done with compressed air using the RAPID AIR SYSTEM, and by vacuum on the Maximus RE. Together with the sealing tool, the forming tool makes up the basic tool set.

Basic length of the machine frame. It largely determines the space the thermoforming packaging machine requires and can be extended with extension modules on several models. At VARIOVAC, the total frame length ranges from 2.5 m to 9.0 m on the Optimus and from 4.0 m to 30 m on the Primus.

Powerful vacuum packaging machines for high packaging volumes and daily use. They feature a 10-programme control system with time and sensor control, double-seam sealing and a choice of chamber sizes. They are used in the food and non-food industries and in catering.

Gas analysers check the gas composition in modified atmosphere packs and support quality assurance. They measure residual oxygen and gas composition, from spot checks to real-time INLINE monitoring directly in the sealing tool. If deviations occur, the INLINE system stops the packaging process automatically.

System that feeds protective gas into the pack for modified atmosphere packaging (MAP). On the Optimus SE/SEL, the gas flushing unit is available as an option. External gas mixing systems provide the right gas mixture, and gas analysers then check the composition inside the pack.

Gas mixing systems blend gases precisely to create the required protective atmosphere for packs. VARIOVAC offers external two- or three-component gas mixers that can be combined with the Maximus RE, Optimus, Primus, Rotarius, Linus and the chamber machines, among others. In addition, gas analysers check residual oxygen and gas composition.

System for packing products that protrude up to 55 mm above the tray rim. It is used on the Optimus EasySkin, which can therefore skin-pack tall products such as meat and fish. By comparison, the Rotarius tray sealer handles up to 25 mm of product protrusion.

Filling freshly cooked food directly into the pack while hot. Combined with steam sterilisation and pasteurisation, it significantly reduces the microbial load, giving steam-packed food a shelf life of up to 21 days.

The distance by which the film web is advanced through the machine in each cycle. It determines how long a pack format can be in the direction of travel. The Maximus RE offers 200 to 320 mm in 6 steps, the Primus MP up to 1,200 mm.

Industrial-grade machine control system (IPC). It is operated via a touchscreen, for example a 10-inch screen on the Optimus SE/SEL and a swivelling 12.1-inch display on the Optimus MP. The Rotarius (7-inch) and the Linus 1100 (10-inch) also use IPC control.

Gas analysis carried out directly in the sealing tool during production. The inline system monitors the gas composition in real time and stops the packaging process automatically if deviations occur.

This specification describes how the packs are arranged in the tool: '2 lanes / 1 row', for example, gives 2 packs per cycle. Lanes run side by side across the direction of travel, while rows follow one another in the direction of travel. After cutting, multi-lane formats can be merged into a single lane with the Variotrack.

Merges packs from multiple lanes and rows into a single lane. This simplifies downstream processes such as metal detection and checkweighing. At VARIOVAC, this is the job of the Variotrack, which merges up to 4 lanes.

Fully automatic inline tray sealer for industrial tray packaging. The series comprises the Linus 650 and Linus 1100, both with 80 storable programmes. The Linus 650 achieves up to 15 cycles per minute, around 60 trays per minute, and can be combined with a tray denester, filling station, labeller or pick-and-place robot.

Cutting method that uses rotating circular knives to separate the film web lengthwise. Together with cross-cutting, it separates the sealed packs, which then leave the machine on the discharge conveyor. Multi-lane formats can subsequently be merged into a single lane with the Variotrack.

In a formal acceptance, a machine is tested before it is delivered or commissioned. VARIOVAC offers the factory acceptance test (FAT) in the showroom in Zarrentin, also digitally via VARIOVAC Studios on request, as well as the site acceptance test (SAT) at the customer's premises. For MedicalLine machines, documentation of the FAT and SAT is optionally available.

In modified atmosphere packaging, the air in the pack is replaced with a gas mixture to extend shelf life. Carbon dioxide, nitrogen and oxygen are most commonly used, matched to the specific product. MAP is suitable for sensitive food from fresh meat to baked goods and is also used in the non-food and medical sectors.

The VARIOVAC Maximus RE is the most compact thermoforming packaging machine on the market. At a machine length of 2.2 m, it is considerably more compact than the Optimus. With an output of 6 cycles per minute, it is particularly suited to smaller artisan and industrial producers and closes the gap between the semi-automatic tray sealer (VARIOVAC Rotarius) and the thermoforming packaging machine for medium-sized production environments (Optimus). Unlike all other VARIOVAC thermoforming packaging machines, the Maximus RE creates its pack cavities by vacuum forming. Like every VARIOVAC thermoforming packaging machine, the Maximus RE stands out for features such as VARIOVAC's signature hygienic design.

Packaging solutions for sterile medical goods. This includes the MedicalLine thermoforming packaging machines, designed for cleanrooms of ISO classes 7 to 9, with processes that can be validated according to IQ/OQ/PQ. Examples include prefilled syringes, infusion bags and wound care sets.

Packaging solution for sterile medical devices. For this purpose, VARIOVAC offers the Optimus MedicalLine and Primus MedicalLine machines. They are designed for cleanrooms of ISO classes 7 to 9 and process materials such as Tyvek®, medical paper and rigid and flexible films.

Pack in which several layers of product are stacked on one bottom film and sealed separately, so that each layer can be opened individually. Typical products are sliced sausage, ham and cheese. Compared with MAP packs, up to 23 % less plastic waste is produced, and the Primus MP handles up to three layers.

Equipment variant for particularly demanding applications. VARIOVAC offers it as the Optimus MP and the Primus MP. Both process bottom films of up to 1,000 µm, and the Primus MP can also produce multi-layer packs (MLP).

Evacuation method in which the top film is narrower than the tool chamber, so that air can escape at the sides. An alternative to edge evacuation.

Packaging solutions for products outside the food and medical industries. Examples include turned metal parts, screws, pipe clamps or hygiene products such as toothbrushes and razors. Vacuum, skin and sealing protect them from moisture, corrosion, dust and mechanical damage.

The VARIOVAC Optimus is a thermoforming packaging machine and the entry-level model for automated product packaging. Its frame length of 2.5 to 5.5 metres makes it more compact than the Primus. With an output of 13 cycles per minute, it is ideally suited to medium-sized production environments and closes the gap between the packaging machine for small artisan producers (VARIOVAC Maximus RE) and the one for large industrial applications (VARIOVAC Primus). The Optimus forms packs quickly and precisely with compressed air, using the VARIOVAC Rapid Air System (RAS). Like every VARIOVAC thermoforming packaging machine, the Optimus stands out for features such as VARIOVAC's signature hygienic design and the quick-change system.

The Optimus EasySkin is a variant of the Optimus thermoforming packaging machine for skin applications. It handles products with an especially large protrusion of up to 55 mm and works with a chain-guided, preheated top film.

The Optimus MedicalLine is a variant of the Optimus thermoforming packaging machine designed specifically for packaging medical devices. It achieves up to 12 cycles per minute and processes film widths of 320 to 460 mm and pack depths of up to 125 mm. The frame length of 2.5 to 5.5 m can be extended with extension modules of 1.0 to 3.5 m.

The Optimus MP is a variant of the Optimus thermoforming packaging machine with Multi-Performance equipment for demanding applications. It processes bottom films of up to 1,000 µm, film widths of up to 460 mm, index lengths of up to 600 mm and pack depths of up to 125 mm. It is used in the food, non-food and medical sectors when the Optimus and Optimus SE/SEL reach their technical limits.

The Optimus SE is a pre-configured variant of the Optimus thermoforming packaging machine. With frame lengths starting at 3 m, it comes with standard equipment and short delivery times.

The Optimus SEL is a pre-configured variant of the Optimus thermoforming packaging machine. With frame lengths starting at 3.5 m, it comes with standard equipment and short delivery times.

Cutting methods for sealing trays: with an outside cut, the sealing film is cut outside the tray rim; with an inside cut, inside it. The maximum film width depends on the method; on the Linus 1100 it is 410 mm for an outside cut and 350 mm for an inside cut.

Solutions for packaging a variety of products. VARIOVAC groups them by the application areas Food, Non-Food and Medical and by seven packaging methods: sealing, MAP, vacuum, skin, steam, shrink and MLP. They include suitable machines, peripheral equipment and consumables such as films, trays and bags.

Maximum depth or height of the formed pack. It depends on the machine type: the Optimus SE/SEL reaches up to 110 mm, the Primus up to 135 mm and the Primus MP 195 mm. For taller products in skin packs, the product protrusion above the rim is added on top.

The designation follows the pattern 'lanes.rows': PG 2.3, for example, stands for 2 lanes and 3 rows, which gives 6 packs per cycle. Changing the pack format requires a tool change in which the forming and sealing tools, cutting system and discharge conveyor are exchanged. How large a format can be depends on the machine's film width and index length.

Property of a pack that allows it to be opened easily at the seal seam. VARIOVAC regularly tests films for formability, sealability, appearance and peelability.

Thermoforming packaging machine series for high cycle rates (up to 20 cycles per minute). With module lengths of 5 to 12 m, film widths of 320 to 560 mm and pack depths of up to 135 mm, it processes flexible and rigid films for food, non-food and medical applications. A four-column lifting system and an integrated recooler with no water consumption are part of the equipment.

Primus variant designed specifically for packaging medical devices. It achieves up to 25 cycles per minute, frame lengths of 5.0 to 24.0 m, film widths of 320 to 720 mm and pack depths of up to 190 mm. Its hygienic stainless steel design is fully cleanroom-compatible, and quick-change systems make format and product changes easier.

High-end version of the Primus with Multi-Performance equipment. It offers frame lengths of 5 to 30 m, film widths of 320 to 660 mm, index lengths of 200 to 1,200 mm and a pack depth of 195 mm. As the only VARIOVAC machine, it handles all seven packaging methods including MLP with up to three separately sealable layers, and the RAPID AIR SYSTEM comes as standard.

Umbrella term for the finished packaging that encloses the product. It protects the product from environmental influences and, depending on the process, can be sealed, vacuum-packed, filled with protective gas or designed as a skin pack. If required, it can be easy to open or resealable.

Height by which a product projects above the rim of the bottom film or tray. It is a key figure for skin packs: the Rotarius handles a product protrusion of up to 25 mm, the Optimus EasySkin with its High-Dome system up to 55 mm.

Gas or gas mixture that replaces the ambient air in the pack in modified atmosphere packaging (MAP). Carbon dioxide, nitrogen, oxygen or a mixture of these gases is usually used, matched to the product.

The Quarree leak tester performs non-destructive leak testing of packs in a water bath, for reliable leak detection. It is used in particular for MAP packs, and packs without defects can still be used afterwards. The device measures 890 x 600 x 1,200 mm externally, offers a usable space of 620 x 350 x 300 mm and runs on 230 V.

Forming the film with compressed air. The process, developed and protected by VARIOVAC, forms the bottom film in the forming tool quickly and precisely, often without pre-heating. It comes as standard on the Optimus SE/SEL, the Optimus EasySkin and the Primus MP, among others.

Option that allows a pack to be closed again after it has first been opened, for example with a zipper. Sealed packs can optionally be made resealable, for instance for cold cuts, grated cheese, nuts or pastries.

Proportion of oxygen that remains in a modified atmosphere pack after packing. Gas analysers regularly check residual oxygen and gas composition, ensuring product safety and compliance with legal requirements.

The Rondo leak tester reliably tests packs for leaks in a water bath. The tabletop version works non-destructively and independently of the mains: an injector generates the negative pressure of up to 200 mbar. At 14 kg and Ø 400 x 330 mm, the device is compact and light.

Semi-automatic tray sealer with a rotary table for efficient packaging processes. With its dual-tool system, it achieves 4 to 8 cycles per minute on a footprint of just 1.6 m² and processes trays up to 100 mm deep for MAP and skin. Tools can be changed without any aids.

Process that closes the pack tightly by fusing the top and bottom films together. As a packaging method in its own right, sealing protects food, non-food and medical items from environmental influences and is particularly suitable for products packed in a normal atmosphere. If required, sealed packs can be made resealable.

Film that is bonded firmly to the bottom film or tray by heat and pressure during sealing, closing the pack airtight. VARIOVAC supplies films as consumables, including lidding films, and tests them for formability, sealability, appearance and peelability. With trays, the tray sealer cuts the sealing film using an outside cut or inside cut.

Part of the sealing tool that seals the top and bottom films together. Customised sealing plates are available for special pack formats and applications. On the Optimus SE/SEL, a full-surface sealing plate is part of the standard equipment, and frame sealing plates are available as an option.

Area of the machine where the top and bottom films are sealed together. Here the top film is placed over the filled cavities and closed in the sealing tool using heat and pressure, creating the seal seam. Depending on the packaging method, the pack is evacuated or filled with protective gas beforehand.

The sealing tool consists of an upper and a lower part and is responsible for sealing the pack. Together with the forming tool, it makes up the basic tool set and is exchanged when the format changes. Depending on the version, sensors check quality directly in the tool, and inline gas analysis measures the gas composition there in real time.

Joint between the top film and the bottom film or tray, created by heat and pressure during sealing. It closes the pack airtight. The integrity of film and seal seam can be tested non-destructively in a water bath with the Rondo and Quarree leak testers.

Packaging method in which heat makes the film fit tightly around the product. The product is vacuum-packed and sealed in a formed bottom film and then passes through a shrink tunnel. Typical products are meat, poultry, sausage and cheese.

Specially developed film for shrink packaging. After evacuation and sealing, heat in the shrink tunnel shrinks it tightly around the product so that it adapts exactly to its shape.

Station through which evacuated and sealed packs pass in shrink packaging. Heat shrinks the film tightly around the product, leaving no excess film.

Acceptance of the machine directly at the customer's site. A VARIOVAC technician on site makes sure that the machine runs smoothly. The SAT complements the factory acceptance test (FAT) in the showroom in Zarrentin, and for MedicalLine machines, documentation of the FAT and SAT is available on request.

In this packaging method, the top film fits tightly around the product like a 'second skin'. It holds the product in place on the bottom film or tray and is particularly suitable for high-quality food such as meat, fish, poultry and cheese. Non-food products such as clamps can also be packed in this way.

Flexible top film for skin packaging. It fits tension-free around the product like a second skin and seals it across its surface onto a rigid bottom film or tray.

Packaging method in which the air in the pack is displaced by steam (e.g. during hot filling with VarioSteam). Freshly cooked dishes are filled hot, and the steam displaces the oxygen before sealing. Soups, sauces, meat and fish dishes or meals packed in this way keep for up to 21 days.

Compact vacuum packaging machines for smaller businesses with limited space. They reach up to 99.8 % vacuum and feature double sealing as standard, with cut-off or wide sealing as options. An integrated cleaning programme, quick-start function and automatic service notification are included.

Thermoforming packaging machines pack products fully automatically. The bottom film is unwound from the film mandrel and transported into the forming tool. The forming tool consists of an upper and a lower part, and this is where the bottom film is heated and formed. Forming is done either purely by vacuum (as on the VARIOVAC Maximus RE) or with compressed air (VARIOVAC Rapid Air System). The film with its formed cavities then moves into the loading area. Here the product (e.g. sausage or cheese) is placed in the cavities by hand or by robot. To prevent heavy packs from sagging, pack guide rails are available for the different formats. Next, the top film is laid over the filled cavity and sealed in the sealing tool. The sealing tool also consists of an upper and a lower part. For certain products, the top film has to be formed as well; this takes place in the top film forming station. Sealing the top film onto the bottom film creates a seal seam. From this point on, the products are protected from environmental influences and keep for longer, because the ambient air has been removed from the pack or replaced with protective gases using one of several methods. In the next step, the individual packs are separated (cross-cutting and longitudinal cutting). Various knives can do this: guillotine, punch, circular knife, rotary shear cutter or crush knife. Depending on the technology and packaging material used, the finished packs can be opened very easily or even resealed. Finally, the individual packs leave the machine on a discharge conveyor. From there, the packs can be transferred to a line converger (Variotrack), where they are conveyed individually.

In most cases, 'tool' means the forming tool or the sealing tool, not a hand tool such as a hammer or screwdriver. Both consist of an upper and a lower part and together make up the basic tool set. The Variocart tool trolley is available for transport and storage, and the Variolift lifting aid for ergonomic changeovers.

When the pack format changes, the machine has to be converted, for example when three sausage packs are to be produced side by side instead of two. This involves changing the forming and sealing tools, the cutting system and the discharge conveyor.

Unit that heats the top film before sealing. On the Optimus EasySkin it is tracked, ensuring that the film wraps the product without tension.

Unwinds the top film and guides it over the packaging area to the sealing station. There it closes the filled cavities. On the Optimus EasySkin, it is additionally pre-heated with chain guidance so that it wraps the product without tension.

Pre-formed packaging container that is sealed with a film on a tray sealer. VARIOVAC supplies menu trays, MAP trays, brine trays and its own Euro freshness boxes, perfectly matched to the Rotarius and Linus tray sealers.

Machine that seals pre-formed trays with a film (e.g. Rotarius, Linus). The Rotarius works semi-automatically with a rotary table and suits small businesses, while the Linus models run fully automatically inline for industrial output. VARIOVAC also supplies suitable trays such as meal trays, MAP trays and Euro fresh boxes.

Packaging method in which the air is drawn out of the pack to extend shelf life. The pack is then sealed, entirely without preservatives. The method is suitable for food from fresh meat to nuts and protects non-food and medical products from moisture, corrosion and dust.

Component that generates the negative pressure in the pack; its capacity is stated in m³/h. The Maximus RE has a built-in 63 m³/h vacuum pump, while the Optimus SE/SEL works with 100 m³/h. The single-chamber machines feature an integrated cleaning programme for the vacuum pump.

Tool trolley for transporting and storing the machine's forming and sealing tools. The configurable stainless steel trolley carries up to 550 kg and offers up to 5 slots. It is compatible with the Maximus RE, Optimus and Primus, among others.

This lifting aid provides ergonomic support during tool changes and when changing film rolls. The stainless steel lifting aid carries up to 200 kg, covers a lifting range of 60 to 1,600 mm and is operated by hand crank. Its stainless steel construction makes it suitable for cleanrooms.

This pack stacker divides the continuous flow of packs from the thermoforming packaging machine into stacks, for example for packing into cartons. It connects to the outfeed of the machine. In addition, the Variotrack merges several lanes of packs into a single lane.

Hot-filling process: freshly cooked products are filled hot and the air is displaced by steam. The process is suitable for soups, sauces, stews, meat and fish dishes and meals, which then keep for up to 21 days. Suitable filling and dosing systems for 50 to 5,000 ml, cold or hot, are available for filling.

This line converger merges several lanes of packs into a single lane, which simplifies downstream processes such as metal detection and checkweighing. It handles up to 4 lanes and is available as Eco 2.0 with frame widths of 360 and 460 mm and as 3.0 with 320 to 460 mm. It can be combined with all thermoforming packaging machines in the food line, from the Maximus RE to the Primus MP.

The company's own foundation, whose work includes Ukraine relief. It was founded in 2022, and more than 100 Ukrainians have been taken in as part of its aid for Ukraine. Anyone who wishes to help can make a donation to the foundation.

Sales portal for internal and external users. The portal is available at salesport.variovac.de and brings together sales information for internal and external use.

Live video conferencing from the VARIOVAC showroom, for example for digital factory acceptance tests and training. Modern, portable video equipment shows the machine live and enables detailed presentations and explanations. Digital factory acceptance tests are available on request and save travel.

Solution for printing on packs: formats with several rows and lanes are printed with just one printer. An X-Y traversing unit moves the printer across the film, which applies information such as the best-before date, batch number or barcodes by thermal transfer or inkjet. Vario XY Move is part of VARIOVAC's coding and printing systems.