Use-Case – FS150 Continuous Band Sealer

The Challenge

A medium-sized dry food manufacturer located near Maribor was packing nuts and dried fruit into LDPE and PP bags weighing up to 3 kg. As demand increased, their two manual bar sealers became a limiting factor at approximately 1,200 bags per day.

Operators spent much of their shift manually positioning each bag and waiting for the seal to cool. Variations in temperature and pressure resulted in about 5% of bags requiring rework due to weak or uneven seals, with some open bags only discovered during final inspection. Management aimed to triple their potential output without increasing headcount, while also ensuring consistent seal quality for retail distribution.

Manual Process

The previous process relied on two handheld impulse/bar sealers and a simple conveyor. Bags were filled, manually placed in the sealer, clamped, released, checked, and then packed into cartons. Each seal required the operator’s full attention, including time for the seal to set and cool.

Before Automation:

• Daily output: 1,200 bags per day
• Time per bag: 22.5 seconds per bag (10 s positioning + 10 s sealing/cooling + 2.5 s handling)
• Total time per day: 1,200 × 22.5 s = 27,000 s ≈ 450 minutes (7.5 hours per day)
• Labour cost: 7.5 h × €25/h = €188 per day
• Rework/issues: 5% of bags (about 60 per day) needed resealing and extra inspection

Automated Solution

The business introduced an FS150 Continuous Band Sealer in a vertical setup for bags between 1 and 3 kg. The machine was positioned after the filling station, with one operator responsible solely for feeding filled bags into the infeed and performing a quick visual check.

After Installing FS150 Continuous Band Sealer:

• The machine runs at 60% of its maximum output to ensure reliable operation
• New time per bag: 7.5 seconds per bag (continuous infeed and automatic sealing)
• Total time per day: 1,200 × 7.5 s = 9,000 s ≈ 150 minutes (2.5 hours per day)
• Labour cost: 2.5 h × €25/h = €63 per day
• Quality gains: rework dropped from 5% to 1% (about 60 to 12 bags per day)

At 60% of its rated 13 m/min speed, the FS150 easily manages the current 1,200 bags per day in a small part of a shift, with enough spare capacity to increase to roughly 3,600 bags per day without needing more staff.

ROI Calculation

Investment:
Machine cost: €599
Daily savings: Labour: €188 − €63 = €125 per day
Rework reduction (time/labour): 48 fewer bags per day × 0.5 min/bag ≈ 24 min/day ≈ 0.4 h/day
Rework labour saved: 0.4 h × €25/h ≈ €10 per day
Total daily savings: €125 + €10 = €135 per day
Monthly savings (22 working days): €135 × 22 = €2,970 per month
Payback period: €599 ÷ €135 per day ≈ 4.4 days (less than 1 week)

Even after accounting for setup, training, and occasional maintenance, the real payback period remains under 1 month. In ongoing use, the FS150 continues to deliver savings of around €135 per day in labour and rework, while enabling greater output.

Conclusion

By switching from manual bar sealers to the FS150 Continuous Band Sealer, the food manufacturer near Maribor reduced sealing labour by approximately 5 hours each day, cut rework by 80%, and gained the ability to triple their bagging volume without hiring extra staff. The modest investment and rapid return made this upgrade a straightforward decision.

“The FS150 reduced our sealing time from 7.5 hours to 2.5 hours per day and lowered rework from 5% to about 1%. We recouped the €599 investment in under a week and now have the capacity for over 3,000 bags daily without needing more operators.” — Marko K., Production Manager, NutriPack d.o.o., Maribor (Slovenia)