Doypack filling line: price, composition and capacity
Doypack offers low packaging cost and strong shelf presence, but requires precise film handling: pouch feeding, opening, filling, sealing and seam control. Below are configurations from rotary automatic to full line with cartoning.
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Doypack filling schemes
Rotary automatic on pre-made pouch, piston doser, date marking
- Area
- from 150 m²
- Lead time
- 2-4 months
Automatic pouch feeding from magazine, doser for viscous product, spout cap applicator, group packaging
- Area
- from 400 m²
- Lead time
- 4-6 months
Two lanes, automatic product preparation, seam inspection, cartoning and palletizing
- Area
- from 800 m²
- Lead time
- 6-9 months
What affects a doypack line price
| Budget item | What is included | What affects cost |
|---|---|---|
| Product preparation | Cooking kettle, homogenizer, deaerator, buffer tank | Viscosity, inclusions, hot or cold fill |
| Filling machine | Rotary, grippers, opening unit, sealing and cooling | Capacity and pouch size range |
| Doser | Piston, auger or weighing unit | Product: liquid, viscous, with pieces |
| Spout and cap | Spout applicator, capper | Whether spout packaging is used |
| Control and packaging | Seal integrity check, metal detector, cartoning | Retail requirements and product category |
In doypack, the economics are decided by film and pouch cost. The difference between a ready pouch and forming from a roll changes both the equipment and the packaging cost per unit.
How we calculate doypack filling
- Step 1Determine pouch type
Ready preformed doypack with a rotary machine or forming from roll on a horizontal machine. We calculate packaging cost per unit.
- Step 2Break down the product
Liquid, paste, pieces, powder. We select piston, auger or pump dosing and decide on hot filling.
- Step 3Decide on the spout
Spout with cap, zip-lock or simple seal. Each option is a separate machine unit and its own machine speed.
- Step 4Check seal integrity
Temperature and pressure for the specific film, leak control, rejection. This is the main source of doypack complaints.
- Step 5Assemble estimate and packaging
Filling machine, date coding, group case packing, palletizing, installation, commissioning, training and film supplier selection.
Questions about doypack filling
Up to 5,000 pouches per hour pre-made is more economical: more design flexibility and easier changeover. Above that volume we consider forming from roll.
Product contamination of the seal zone. Solved by correct doser geometry, cut-off and seal integrity control at the exit.
Yes, with a piston doser with enlarged valve passage. Inclusion size is included in the specification.
Detailed materials on the topic
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View calculationCalculate a doypack line
Describe the product, pouch size, presence of a spout and volume. We will compare ready pouches and forming from roll, and provide an estimate.