Eradicating seal contamination, overcoming thick fluid dynamics, and reducing CIP washdown times for a premier European sports nutrition brand
Sports Nutrition Manufacturer
Sports Gels, Liquid Supplements & Syrups
Easy-Tear Liquid Stick Packs & Spouted Pouches
CE Marked,EHEDG Guidelines
June 2025
$795,00+
Munich, Germany
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The client was manufacturing highly concentrated, ultra-viscous carbohydrate energy gels and liquid vitamins. Their generic liquid packaging line was creating a sanitation and profitability nightmare:
Catastrophic Seal Contamination : The thick gels “stringed” and dripped from the nozzles after the fill cycle, contaminating the horizontal sealing jaws. This led to sticky, failed seals, causing severe leakage during shipping and destroying retail boxes.
Inconsistent Dosing Under Pressure : Viscosity changes due to ambient temperature shifts caused pneumatic pumps to over-fill or under-fill pouches, resulting in massive product giveaway and non-compliant labeling.
CIP Washdown Nightmares : Sticky gel residue required maintenance crews to dismantle the entire fluid path with tools, taking over 3 hours for a complete sanitary washdown between flavor changeovers.
Before deployment to Munich, the line was subjected to a rigorous FAT using the client’s actual viscous formulas, targeting the following non-negotiable metrics:
EIXPACK engineered an IP65-rated, heavy-duty liquid packaging architecture specifically optimized for high-viscosity fluid dynamics and European sanitary mandates.
We replaced standard valves with a servo-driven diving nozzle system equipped with a positive mechanical shut-off. The nozzle dives deep into the pouch and rises exactly in sync with the fluid level, snapping shut instantly. Zero stringing. Zero drips.
Eradicating pneumatic inconsistencies, each lane is powered by independent servo-piston pumps. The master PLC pushes thick gels with absolute force, ignoring viscosity fluctuations and locking in ±0.1g volumetric accuracy.
The entire fluid delivery path features sanitary tri-clamp connections and self-draining angles. Operators can flush the system or strip the contact parts by hand in minutes, reducing contamination risks.
Operational data from the first six months of production demonstrated massive efficiency gains and brand protection:
Spoilage Claims Eliminated: The anti-drip system achieved 0% seal contamination, completely eradicating costly retailer chargebacks due to sticky, leaking boxes.
Labor Overhead Slashed: Reducing the sanitation teardown time saved the facility an estimated 250+ labor hours per quarter.
Precision Profitability: Eliminating high-value product giveaway directly added an estimated €42,000 back to the bottom line annually.
Thick liquids are prone to "stringing." EIXPACK neutralizes this via proprietary diving nozzles with positive mechanical shut-off valves. The nozzles lower directly into the pouch and rise in perfect sync with the fluid fill level. At the exact millisecond the dose is complete, the internal valve snaps shut, mechanically cutting the fluid stream and ensuring a 0% drip rate. The seal zone remains perfectly clean.
Yes. Generic pneumatic pumps struggle to push high-viscosity gels, leading to short-fills and slow cycle times. EIXPACK utilizes robust servo-driven ceramic piston pumps. The servo motors generate massive, highly controlled torque, pushing thick liquids effortlessly while maintaining a micro-tolerance dosing precision of ±0.1g, regardless of temperature-induced viscosity changes.
We engineer our machines to minimize labor-intensive downtime. The EIXPACK liquid filling system is built on an IP65 sanitary washdown architecture. All fluid paths utilize polished 316L stainless steel, self-draining geometries, and quick-release sanitary tri-clamps. This allows operators to execute complete Clean-In-Place (CIP) flushing or fully dismantle the contact parts by hand in under 30 minutes.
Absolutely. EIXPACK systems are strictly designed in accordance with EHEDG (European Hygienic Engineering & Design Group) guidelines and FDA cGMP standards. We eliminate dead corners where bacteria can harbor, utilize food-grade and pharma-grade seals (like Viton and PTFE), and provide complete material traceability (MTR) to pass the most rigorous global facility audits.
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