Empowering Three Major Industries: Huapack’s Comprehensive Spouted Pouch Packaging Solutions
Spouted pouches, known for their lightweight nature, portability, and excellent shelf presence, are becoming a vital supplement or alternative to traditional bottles and jars. They are widely used in food & beverage, daily chemicals, and medical & healthcare sectors. Shanghai Huacheng Packing Machinery Co.. Ltd. (Huapack) offers three major equipment series: the 180SP Series (Form-Fill-Seal from roll film), the 180GP Series (Premade pouch filler/spouter), and the ZGY-3000 Series (Filling & Capping).
This guide provides a one-stop selection reference based on industry pain points, equipment selection, and real-world case studies.
I. 180SP Series: Inline Form-Fill-Seal (FFS) from Roll Film,all-in-one process
This series integrates roll film forming, automatic spout welding, and precision filling into one seamless operation.
Cost Efficiency: Reduces material costs by 20%–30% compared to traditional premade spouted pouches (based on internal estimates; actual savings vary by material and volume).
Performance: Stable capacity of 30–90 bags/min (under standard conditions), supporting multi-lane expansion.
Design: Modular layout, quick changeover, small footprint, and minimal manual intervention.
1.1 Food & Beverage: Versatile Compatibility
Liquid Foods (Juice, Tea, Yogurt): Piston or flowmeter dosing with accuracy within ±1.5ml; equipped with anti-drip suck-back devices.
Sauces & Condiments (Ketchup, Mayo, Honey): Upgradable to auger feeding with heated/insulated hoppers; automatic spout cleaning prevents sealing contamination.
Baby Food (Fruit Puree, Formula): Features enclosed feeding and CIP (Clean-in-Place) quick-release cleaning modules.
Case Study: Tomato Ketchup Project for a Guatemala Food Company
Background: A high-end condiment enterprise producing 300g spouted pouches for retail and catering.
Pain Point: Manual filling of premade pouches was slow (15 bags/min), and residue on the spout caused a 3%-5% seal failure rate.
Solution: 180SP with auger dosing + spout cleaning device + dual-station heat/cold welding.
Feedback: Speed stabilized at 30-35 bags/min. The manager noted: “Huapack’s equipment ensures our ketchup ‘stands straight and seals tight’.”
1.2 Daily Chemicals: Lightweight Alternative to Rigid Plastic
Compared to HDPE rigid bottles of the same capacity, spout pouches reduce plastic usage by approximately 70% and significantly lower warehousing and transportation costs. Personal care products vary widely in viscosity (ranging from aqueous solutions at 1 cps to pastes at 100,000 cps), and some contain surfactants, salts, or corrosive ingredients, placing higher demands on filling accuracy, seal reliability, and equipment materials.
Household cleaning products (laundry detergent, fabric softener, hand soap, dishwashing liquid, 500 ml–2,000 ml)
Large-capacity spout pouches must meet the dual requirements of high-speed filling and highly reliable sealing. The Huacheng 180SP series can be expanded to a dual- or quad-outlet configuration, increasing speed to over 120 bags per minute. For large bag sizes, closed-loop control of heat sealing pressure is employed: force is distributed evenly across the wide sealing area, preventing localized cold seals or melt-through. For products containing surfactants (prone to foaming), the filling head is equipped with an anti-foaming back-suction device to reduce foam generation during filling and prevent contamination of the bag opening. All equipment components in contact with the product are made of 316L stainless steel and PTFE seals, offering corrosion resistance, acid and alkali resistance, and washability.
Cosmetics and Skincare Products (Serums, Lotions, Sunscreens, High-Value Small-Volume Formulations)
High-value products are extremely sensitive to filling accuracy and packaging quality. The 180SP series features servo metering, where a servo motor controls the rotation angle to achieve high-precision filling within ±1 ml, making it particularly suitable for small-volume packaging ranging from a few milliliters to several dozen milliliters. The nozzle welding process employs a dual-station system combining constant-temperature hot welding and cold setting. Rapid cooling after welding ensures a smooth, burr-free weld, preventing scratches to consumers’ lips or hands and enhancing the unboxing experience. Additionally, the equipment can be equipped with a laminar flow hood (HEPA-filtered) to meet cosmetic GMP requirements for filling area cleanliness.
Travel-Size Products (Shampoo, Body Wash, 30–100 ml)
Small batch sizes and rapid product changeovers are typical characteristics of travel-size production. The 180SP series supports low-volume filling and features an automatic clamp adjustment function, allowing the equipment to automatically adjust parameters such as pouch width without the need to manually tighten or loosen screws. This design is particularly well-suited for contract manufacturers and e-commerce businesses requiring rapid product switching for promotional campaigns.
1.3 Medical & Healthcare: Clean, Precise, and Traceable
Pharmaceutical and health products (oral solutions, medical irrigation solutions, disinfectants, eye drops, topical gels, etc.) are subject to strict regulations regarding packaging sterility, seal integrity, dosing accuracy, and data traceability, and typically must comply with GMP, ISO 13485, or relevant FDA guidelines. Huacheng’s spout-sealing film winding machine can be equipped with the following specialized modules to meet pharmaceutical-grade production requirements:
CIP System: The filling lines support Clean-in-Place (CIP) operations, allowing for complete machine sterilization without disassembly, in compliance with the pharmaceutical industry’s “closed-loop” requirements. All piping is designed to eliminate dead zones.
UV Sterilization: UV-C lamps mounted along the bag track continuously irradiate the surface of the packaging materials to reduce the initial microbial load.
High-Precision Filling and Sealing Validation
For low-viscosity liquids such as oral solutions and drops, a ceramic rotary piston pump is used, achieving accuracy within ±0.5%. Based on standard test media, an application example: A medical disinfectant manufacturer using the 180SP series to package 500ml spout pouches of medical disinfectant achieved safe packaging of flammable liquids by equipping the machine with an explosion-proof motor, anti-static grounding, and fully sealed piping; Third-party testing results during equipment acceptance showed a filling accuracy of ±0.8 ml and a seal integrity vacuum decay test pass rate of 99.96%, helping customers meet the relevant packaging requirements for medical device registration.
Household cleaning products (laundry detergent, fabric softener, hand soap, dishwashing liquid, 500ml–2000ml): The Huacheng 180SP series can be expanded to dual- or quad-outlet configurations, increasing speed to over 120 bags per minute. Closed-loop control of heat sealing pressure ensures a secure seal on large bags.
1.4 Overview of the 180SP Series’ Key Advantages
Film-to-bag conversion reduces material costs: By eliminating the bag-making and transportation steps associated with pre-made bags, costs are reduced by approximately 20%–30%.
Fully Automated Integrated System: From unwinding, forming, and sealing to filling and cutting, the entire process requires no manual intervention.
Adjustable Filling Accuracy: Piston pumps, flow meters, or servo screw feeders can be selected based on material characteristics. Filling accuracy is ≤±1.5 ml for liquid products and ≤±2 g for high-viscosity pastes.
II. 180GP Series Bag-Filling and Sealing Machine: High-End Packaging for Pre-Made Bags, Versatile and Integrated
This series is specifically designed for stand-up pouches with direct-drink spouts and is suitable for mid-to-high-end liquid and paste products (such as baby food, functional beverages, and ketchup). It features an integrated bag-feeding, filling, and sealing machine that automates the entire process: bag retrieval → bag opening → filling → sealing → capping.
Outstanding visual appeal and brand premium: Pre-made pouches can be shaped into various forms, such as bottles or leaves. The addition of a spout combines the convenience of a bottle with the portability of flexible packaging, significantly enhancing the product’s visual appeal on the shelf.
Minimal packaging waste: The equipment features detection functions that prevent filling if no bag is present or if the seal is not secure. If a bag is not opened or fails inspection, the system sends a “no discharge” command to the filling station, preventing waste of expensive materials (such as bird’s nest or serums) and eliminating the hassle of cleaning.
Functional Integration and Flexibility: The system integrates automatic bag retrieval, opening, filling, spout welding, and sealing into a single unit, with expandable functional modules for hanging holes, zippers, and irregular shapes.
Production Safety and Hygiene Standards: The entire machine is constructed from 304/316 stainless steel, and the filling system can be connected to a CIP (Clean-in-Place) automatic cleaning system, meeting GMP requirements. The fully automated process reduces manual contact, minimizing hygiene risks.
Operating Costs and Efficiency: Depending on actual operating conditions, the machine typically replaces 4–6 semi-automatic operators (specific numbers depend on production line configuration and operator proficiency); full servo control ensures filling accuracy (with errors typically less than ±1%), low mechanical failure rates, and minimal downtime for maintenance.
III. ZGY-3000 Series: Spouted Pouch Filling & Capping
A filling and capping machine specifically designed for spout pouches (flexible packaging with spouts), integrating filling, cap sorting, cap placement, and capping into a single unit. It is suitable for liquids and pastes such as purified water, fruit juice, milk, soy milk, jelly, jam, and chocolate sauce.
Key Features
Filling Accuracy and “Drip-Free” Design: Utilizes servo-controlled piston or flowmeter filling, achieving accuracy of ±0.3%–0.5%, which is particularly critical for high-value products (bird’s nest, concentrated pure juice, cosmetics). The filling head features a suction-back function to ensure no residual liquid drips, preventing seal contamination, subsequent mold growth, or improper capping.
Perfect Capping Quality and Torque Control: Utilizes constant-torque capping to ensure consistent tightness for every cap, preventing leakage or consumer difficulties in opening. The automatic cap feeding and positioning system uses a vibrating bowl or elevator to feed caps and automatically apply them, ensuring full automation and eliminating manual contamination.
Excellent Hygiene and Safety Standards: The piping features a dead-space-free design and supports CIP (Clean-in-Place) cleaning, allowing for disinfection without disassembly, in compliance with HACCP and pharmaceutical-grade standards. Lower packaging material costs: Spout pouches use approximately 60%–70% less plastic than rigid bottles of the same capacity, aligning with the trend toward reducing plastic use and protecting the environment while simultaneously lowering packaging costs.
Case Study: A Fruit and Vegetable Beverage Engineering Technology Center in Guizhou — Blueberry Juice Spout Pouch Packaging Project
Client Background: Specializing in the R&D and production of premium fruit and vegetable juices, the client required packaging for 200ml blueberry juice (containing fine fruit pulp particles).
Challenges: The original semi-automatic filling line suffered from significant accuracy fluctuations (±5ml), and occasional leaks at the spout welds led to a shortened shelf life.
Huacheng Solution: The 180SP series is equipped with a piston-type metering system (optimized for fluids containing particles) and a back-suction anti-drip filling head; nozzles utilize automatic feeding via a vibrating feeder combined with a constant-temperature heat-sealing process; UV sterilization units were added to the bag and cap sorting tracks; supports CIP cleaning and nitrogen flushing to prevent oxidation; servo-driven capping torque can be adjusted online via the touchscreen.
Results: Filling accuracy improved to within ±1ml; weld seals passed airtightness testing; product shelf life extended by 30%. On-site measurement data from the client.
IV. Selection Comparison & Recommendations
4.1 Representative Model: 180SP Film Roll Machine
Input Format: Film roll
Core Processes: Bag forming + Spout welding + Filling + Sealing
Applications: High-volume production, cost-sensitive operations, bag production from scratch
Material Costs: Lowest (eliminates pre-made bags)
Changeover Speed: Relatively fast (mold replacement)
Typical Industries: Food and beverage, personal care, pharmaceuticals
4.2 Representative Model: 180GP Bag Feeder
Input Format: Pre-made bags (with spouts)
Core Processes: Bag retrieval + Bag opening + Filling + Spout sealing + Sealing
Applications: Irregularly shaped bags, high-end aesthetics, frequent product changeovers
Material Cost: Moderate (cost of pre-made bags)
Changeover Speed: Fastest (one-button clamp adjustment optional)
Typical Industries: Infant and toddler food, functional beverages, premium sauces
4.3 Representative Model: ZGY-3000 Filling and Capping Machine
Input Format: Finished pouches with pre-welded spouts
Core Processes: Filling + Cap Alignment + Capping
Applications: Post-processing filling and capping for pouches with pre-welded spouts
Material Cost: Depends on upstream processes
Changeover Speed: Relatively fast (servo parameter adjustment)
Typical Industries: Beverages, jams, cosmetics, pharmaceuticals
Selection Advice:
Seeking Lowest Material Cost: Choose the 180SP Roll Film Series.
Need Shaped Bags or Rapid Variety Changeover: Choose the 180GP Premade Series.
Already have spouted bags and only need filling/capping: Choose the ZGY-3000 Series.
Huapack can provide a Full Turnkey Solution integrating all three stages to ensure seamless operation.
V. Conclusion
From roll film to finished spouted pouches, Huapack provides mature, stable, and verifiable solutions across the food, chemical, and medical sectors. Whether you prioritize cost, shelf aesthetics, or high-precision capping, our technical team is ready to support your project.
Contact Huapack today for technical specifications or to request a sample test.
