Spout 10

“To Design A Two Way Spout Sachet For Shampoo And
Shower gel”
Submitted in partial fulfillment of the requirements
of the degree of
Bachelor of Engineering
in
Printing & Packaging Technology
by
Anurag Ganapathi 116A4002
K Nishant 116A4009
Ishwar Shenoy 116A4019
Vishal Manikandan 116A4026
Under the Guidance of:
Prof. Prasad Balan Iyer
Department of Printing & Packaging Technology
SIES Graduate School of Technology
2019-2020
CERTIFICATE
This is to certify that the mini-project entitled “To design a two way
spout sachet for shampoo and shower gel” is a bonafide work of the
following students, submitted to the University of Mumbai in partial
fulfillment of the requirement for the award of the degree of Bachelor
of Engineering in Printing & Packaging Technology.

K Nishant 116A4009
Prof. Prasad Balan Iyer Dr. A. N. Kemkar

Internal Guide Head of Department I/C Principal
MINI-PROJECT REPORT APPROVAL
This mini-project report entitled “To design a two way spout sachet for
shampoo and shower gel” by following students done at SIES –
Graduate School of Technology, Nerul is approved for the degree of
Bachelor of Engineering in Printing & Packaging Technology.

K Nishant 116A4009
Name of External Examiner: --------------------------------
Signature:--------------------------------
Name of Internal Examiner: --------------------------------
Signature:--------------------------------
Date:
Place: Nerul, Navi Mumbai

DECLARATION
We declare that this written submission represents my ideas in my own words and
where others’ ideas or words have been included, we have adequately cited and
referenced the original sources. We also declare that we have adhered to all
principles of academic honesty and integrity and have not misrepresented or
fabricated or falsified any idea/data/fact/source in my submission. We understand
that any violation of the above will be cause for disciplinary action by the Institute
and can also evoke penal action from the sources which have thus not been
properly cited or from whom proper permission has not been taken when needed.
Anurag Ganapathi 116A4002 _____________
K Nishant 116A4009 _____________
Ishwar Shenoy 116A4019 _____________
Vishal Manikandan 116A4026 _____________

Signature
Date:
5
ACKNOWLEDGEMENT
It was a great pleasure to work on this topic and present this report. We would like to express
our gratitude and sincere thanks to all the people who gave us this opportunity to complete this
report. A special thanks to our Project guide Prof. Prasad Balan Iyer and Prof C.S.
Purushothaman sir for placing complete faith and confidence in our ability to carry out this
project and for providing us with their time, inspiration, encouragement, help and valuable
guidance. Without the sincere and honest guidance of our respected sir’s we would not have
been able to reach the present stage.
We would also like to thank our friends and peers for their help and support throughout the
journey.
Mini-Project Team
Anurag Ganapathi
K Nishant
Ishwar Shenoy
Vishal Manikandan
6
ABSTRACT
Shampoo in sachet was introduced many years back as an entry strategy into rural market and
also formed a part of the single use category. The presences of sachet garlands even in a small
retail shop were a common sight. The increase consumption not only in rural area but also as a
part of travel validated the use of sachet. Shower gel as product has been around the market,
yet restricted to a particular segment the shower gels came in plastic rigid containers and found
it difficult to augment the soap market.
This project mainly aims at introducing a new travel friendly pack for shampoo and shower gel
in a two way spout sachet and make this design convenient for customer to carry shampoo and
shower gel. This design will prompt the customer buying a shampoo sachet to try the dual pack.
This could lead to an increase in the trails and usage of shower gels. It would also be an
economic pack and would eliminate the need of rigid container for shower gel.
Key words – Two way Sachet, Shampoo and Shower gel, Spouted pouch, Travel friendly.
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Contents
Page No.
Chapter 1 Introduction 12
1.1 Need 12
1.2 Objective 12
Chapter 2 Review of Literature 13-23
2.1 On basis of existing structure 13
2.2 Sachet filling and forming 15-19
2.2.1 VFFS machine 15
2.2.2 HFFS machine 17
2.3 Material selection criteria 19
2.4 HSPET information 20
2.5 Print repeat length 22
Chapter 3 Methodology 24-51
3.1 Market research 25
3.2 Public opinion survey 28
3.3 Twin spout sachet design 30
3.4 Product design 31
3.4.1 Material selection based on design 31
3.5 Machine feasibility 34-44
3.5.1 VFFS machine 34
3.5.2 HFFS machine Type 1 38
3.5.3 HFFS machine type 2 41
3.5.4 HFFS machine type 3 44
3.6 Costing 48
Chapter 4 Results and Discussions 52-53
Chapter 5 Summary and Conclusion 54-55
5.1 Summary 54
5.2 Conclusion 55
5.3Future scope 55
References 56
8
List of Figures
Figure Figure Caption Page

No. No.
2.1 PET / VMPET / PE structure 13
2.2 VFFS unwinding section 15
2.3 VFFS tensioning unit 16
2.4 HFFS machine drawing 17
2.5 HSPET structure 20
2.6 Print repeat length representation 23
3.1 Twin spout Sachet design 30
3.2 Custom VFFS machine 34
3.3 Custom HFFS machine type 1 38
3.6 Laminate prototype 53
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LIST OF CHARTS
Chart no. Chart Caption Page no.
1. Gender of respondent 28
2. How often do u use body care products 28
3. What do u prefer while traveling 29
4. Would you prefer a travel oriented package 29
List of Tables
Table Table Caption Page

No. No.
2.1 VMPET Data sheet 14
2.2 HSPET Data sheet 22
2.3 HSPET thickness wise application 22
3.1 Annotation for twin spout sachet design 30
3.2 PE-PET-VMPET-PE VS HSPET-VMPET-HSPET 33
3.3 Annotation for custom VFFS machine 35
3.4 Annotation for figure custom HFFS machine type 1 39
3.5 Annotation for figure HFFS machine type 2 42
3.6 Annotation for figure HFFS machine type 3 45
3.7 Comparative study between different machine configuration 47
3.8 Cost summary 51
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List of Abbreviations
In alphanumeric order
AL Aluminum
BOPP Biaxially oriented polypropylene
CPP Cast polypropylene
FMCG Fast moving consumer goods
HSPET Heat sealable Polyethylene terephthalate
NY Nylon
PE Polyethylene
PET Polyethylene terephthalate
VMPET Vacuum metalized Polyethylene terephthalate
VFFS Vertical form fill seal machine
HFFS Horizontal form fill seal machine
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Chapter 1
Introduction
Sachets have played quite a role in mobilizing FMCG products in India. Sachets have now
become popular in the skincare and hair care segment. Sachets make up for more than 75
percent of the total volume of the shampoo segment. Shower gel as product has been around
the market, yet restricted to a particular segment the shower gels came in plastic rigid containers
and found it difficult to augment the soaps market. As a result sales have been quite less as
compared to soap market.
1.1 Need
Since there is no efficient way of carrying shower gel and shampoo together there is a need for
‘travel friendly pack' for it. No smaller portion size for shower gel are available currently in the
market. Aim of the project is to increase the consumption and sales of shower gel in India,
coupled with a handy shampoo portion.
1.2 Objective
The object of the project is to
a. Create a Two way spout sachet for shampoo and shower gel.
b. Service last minute travellers or those just tired of having to lug around a multitude of heavy
flasks and tubes.
c. Reduce the time spent packing toiletry containers that are too bulky to travel with and too
time consuming to use.
d. Make shower gels available in sachet thereby eliminating the use of rigid plastic container
during traveling.
e. Offering other product variants in pack form.
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CHAPTER 2
REVIEW OF LITERATURE
2.1 On basis of existing structure
Figure 2.1 Existing laminate structure
Based on the figure 2.1 Material property
1. PET ( first layer ) - PET film is a polyester film made from stretched polyethylene
terephthalate (PET) and is used for its high tensile strength, chemical and dimensional stability,
transparency, reflectivity, gas and aroma barrier properties, and electrical insulation etc.
Advantages of using PET on the outside
● Excellent Printing Characteristics and finish

● Transparent barrier properties against odor and moisture
● Dimensional stability
Thickness range – 10 – 12 microns
2. VMPET ( middle layer ) - VMPET film is a kind of composite flexible packaging material
that is formed by coating a thin layer of aluminum on the surface of plastic film by special
process. The most commonly used processing method is vacuum aluminum plating method,
which is to pass high temperature under high vacuum state. The metal aluminum melts and
13
evaporates, causing aluminum vapor deposition to accumulate on the surface of the plastic film
so that the surface of the plastic film has metallic luster.
Advantages of using VMPET on the inside layer
● Excellent barrier properties against odor and moisture.
● Provides light barrier against light sensitive products.
● Provides integrity to the structure
Thickness of film used - 10 – 12 microns.
Table 2.1 Data sheet for VMPET
3. PE (Sealing Layer)
Advantage of using PE as sealing layer
● High seal strength.

● Provides good structural integrity.
Thickness of film used – 20 to 50 microns.
14
2.2 Sachet filling and forming
2.2.1 Vertical Form fill Sealing Machine
1. Film unwind and transport
Figure 2.2 Unwind section of VFFS machine
Sachets packaging machine usually use a roll of single sheet material known as roll stock as
displayed in the figure 2.2. Which is feed into the machine at the feeding section the roll is
unwinded with the help of motors.
2. Optional Printing section
The machine can be equipped with a date stamping device (printer), the film is fed over a sliding
roller that registers the position of the date stamp on the package in relation to the horizontal
seal. The film is threaded over a sensor that reads eye marks and controls the position of the
horizontal seal in relation to the printing on the film.
15
3. Film Tensioning and positioning
Figure 2.3 Film Tensioning and Positioning unit
The film is passed through set of breaking rollers which gives tension to the roll the machine is
also equipped with an optical sensor which monitors the edge of the web and aligns it
accordingly as displayed in the figure 2.3.
4. Film Cutting & Folding
Immediately after that, the film is divided with a disc knife into two halves (front and back).
The rear half of the film runs under the sensor that reads the marks on the film and controls the
position of the cross seal with regard to the film print. The front and back halves of the film are
then folded to meet again with the print facing outward.
5. Sachet forming
The Sachets are passed over a former which gives the shape of the sachet.
6. Sachet Sealing and Filling
The liquid or powder product is then dispensed into each sachet by round tubes or flat nozzles.
A special bag straightener can be employed at this step to make sure the packets are perfectly
straight prior to cutting.
16
Next, sealing of the sachet packets takes place. Both sets of sealing jaws are heated to bond the
front and back sheets of film to one another to create sealed packets. The longitudinal (vertical)
vertical seal jaws first close in the space between the filling nozzles or tubes. Then, the cross
(horizontal) seal jaws close to form the bottom seal of one packet and the top of the next. This
creates the distinct 4-side-seal look of the sachet packages.
7. Sachet cutting
A group of pneumatically-driven disc knives can then cut the film vertically if individual
sachets are desired. Perforation knives with an intermittent edge can be used for creating pairs
or triplets of packets divided by perforation. A horizontal cutting station then separates the
filled, sealed, and longitudinally cut packets into individual sachets.
Finished sachets drop into an out feed chute that deposits the bags either onto an out feed
conveyor or directly into a receptacle.
Alternatively, a robotic pick & place device can be used at this point. This device uses vacuum
suction to lift individual sachets, turns them by 90 degrees, and places them onto a special out
feed conveyor. This conveyor has individual lanes that guide each sachet down line.
2.1.2 Formation of Spout pouch by Horizontal form fill seal machine
Figure 2.4 HFFS Machine
17
Sachets packaging machine usually use a roll of single sheet of material known as roll stock
which is feed into the machine at the feeding section the roll is unwinded with the help of motors
as shown in the figure 2.4.
2. Film tensioning and positioning
accordingly. As displayed in the above figure 2.4.
3. Pouch forming
The film is passed through a former where the sachet gets shaped. As shown in the first stage
of the figure 2.4.
4. Vertical Sealing
Vertical seals are made to the film with the help of vertical sealing jaws the seals are in sync
with the repeat length of the roll.
5. Cutting of the pouch
With the help of cutting jaws the pouches are separated into individual blanks.
6. Filling operation and spout attachment
There are two types of filling operations identified
● Filling the pouch with the help of a nozzle (contact filling) and then attaching a spout
to it with the help of spout sealer.
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● Attaching the spout to the pouch and sealing the spout and then the product is filled into
the pouch through the nozzle and capping.
7. Collection
Finished sachets drop into an out feed chute that deposits the bags either onto an out feed
conveyor or directly into a receptacle.
Alternatively, a robotic pick & place device can be used at this point. This device uses vacuum
suction to lift individual sachets, turns them by 90 degrees, and places them onto a special out
feed conveyor. This conveyor has individual lanes that guide each sachet down line.
2.3 Material Selection based on unique forming design
The unique forming technique of the two way spout sachet required necessary alterations to the
existing structures.
Through research it was found that in order to seal the sachet, Front and back layer of the film
used needs to be same. Thus following structures were identified,
1. PE / PET / VMPET / PE
2. HSPET / VMPET / HSPET
In the first configuration
● PE would act as a sealing layer as well printing layer.

● PET layer would act as a barrier layer as well as provide integrity.
● VMPET would give barrier properties for odor, moisture as well as light resistance for
light resistant products.
● PE would act as a sealing layer as well printing layer.
Since the existing structural design is already been tested and widely accepted in the industry.
Adding a PE layer at the top, It does not affect the integrity of the sachet and also does not
chemically reacts with the product filled inside.
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The problem with this structure is that PE does not have excellent printing characteristics as a
result the printing done on PE would have a hazy appearance. Which won’t be desired as it is a
body care product. This can be overcome by graphics.
Second configuration
● HSPET would act as a sealing layer as well as a printing layer

light resistant products.
● HSPET would act as a sealing layer as well as a printing layer.
2.4 HSPET
Figure 2.5 HSPET Structure
Heat Sealable Pet Film is a coextruded, biaxially orientated one side heat sealable polyester
film with a corona treatment on the reverse side. The amorphous seal layer, seals to CPET,
APET, BOPET, glass, coated paper and paperboard. The corona treatment on the reverse side
has good ink adhesion, suitable for various printing. Heat sealable film complies with the
relevant FDA EC directives for food contact applications. The structure of HSPET is shown in
the figure 2.5
Due to the excellent temperature performance of the film (freezer to oven) this is used for the
dual oven able ready meal market either as a lidding film or a bag. Product can be taken from
the freezer and then cooked in the oven or microwave.
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Properties
● Excellent dimensional stability at higher temperatures.
● Good heat sealing performance and strength, the sealing temperature is lower.
● Excellent mechanical properties.
● Excellent printing and metallization.
● Excellent dimensional stability and temperature resistance.
● Strong Sealing strength and sealing performance.
COMPABILITY WITH MACHINE
The film exhibits excellent strength and dimensional stability at high temperatures. Providing
the correct heat seal properties is critical for achieving good pack integrity. The films typically
have a wide operating (heat-seal) window and are very compatible when running through all
types of packaging machines, such as Vertical Form Fill & Seal (VFFS), Horizontal Form Fill
& Seal (HFFS) and overwrap equipment. For more demanding pack types and sizes, Ester has
also developed a high heat-seal strength product. This provides the hermetic weld seal
performance, making the film especially suited for heavier pack weights. The technical
specification and thickness wise applications are given in the table 2.2 and 2.3 respectively.
Applications of HSPET
Heat Sealable PET Film is widely used in sealing seal pharmaceuticals, food, cosmetics, oil,
chemicals, food container industry, because of its appearance, printable , a strong barrier, etc.
Heat Sealable PET Film can be moisture-proof, leak-proof, anti-counterfeiting, to improve
product quality and extending shelf life. It is also used in mosquito coil packaging.
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Table 2.2 Data sheet for HSPET
Table 2.3 HSPET THICKNESS WISE APPLICATION
2.5 Printing on the laminate layer
Preferred technology – Flexographic printing (reverse printing)
Flexographic printing technology has a flexibility to print on a laminate structure. By using

reversing printing we can achieve the excellent glossy appearance that is required for a body
care product.
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Print repeat length required
Figure 2.6 Print repeat length for twin spout sachet
Figure 2.6 displays the print repeat length design due to the unique forming of the sachet.
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CHAPTER 3
METHODOLOGY
WORK DONE
CONCEPT GENERATION
MARKET RESEARCH
PUBLIC OPINION SURVEY
TWIN SPOUT SACHET DESIGNING
FORMING TECHNIQUE
IDENTIFICATION
IDENTIFYING MATERIAL OF
CONSTRUCTION FOR FILM ROLL
MANUFACTURING FEASIBILITY
COSTING OF PROJECT SETUP
FINAL PROTOTYPE
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3.1 Market Research
Available market offerings currently
1. Material Structure – Laminated material
2. Material of construction – CPP / AL / PE
3. Printing – Gravure printing
4. Feature – Moisture Proof
5. Usage – Cleaning supplies
2. Material of construction – PET / VMPET / PE
3. Printing – Flexographic printing
4. Feature – Excellent barrier against air, moisture, puncture
2.Material of construction – PET / VMPET / PE
3.Printing – Flexographic printing
4.Feature – Excellent barrier against air, moisture
25
2.Material of construction – BOPP / AL / PE
3.Printing – Flexographic printing
4.Feature – Barrier against air, moisture
2. Material of construction – PET / VMPET / PE
3. Printing – Gravure Printing
2. Material of construction – PET / AL/ PE
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2. Material of construction – PET / NY/ PE
2. Material of construction – PET / AL/ PE
2. Material of construction – PET / PE, BOPP / PET / PE
4. Feature – Excellent barrier against air, moisture , puncture
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3.2 Public Opinion Survey (176 recorded responses)
1. Gender of Respondent
Chart 1 Gender of respondent
2. How often do you use body care products while traveling?
Chart 2 how frequently body care products are used
Observations – Majority people use some kind of body care products while traveling.
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3. What would you prefer while traveling?
Chart 3 Preference while traveling
Observation - Majority people prefer sachets while traveling.
4. Would you prefer a travel oriented pack for shampoo and shower gel?
Chart 4 Opinion on travel oriented pack
Observation – Majority of people would prefer a travel oriented pack.

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3.3 Twin Spout Sachet design
Figure 3.1 Twin spout Sachet design
Table 3.1 Annotations for Twin spout sachet
Figure no Annotation for Twin spout sachet design

1. Flat sheet of HSPET – VMPET - HSPET
2. Sheet is been transformed into S shape by folding
3. Closed view of the sachet
4. Vertically sealed with top and alternate bottom opening
5. Spouts attached to top and bottom opening
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3.4 Product Details
The main aim is designing a twin spout sachet which has 2 opening at opposite sides. This
design is purely made to hold and use of 2 products in one single sachet.
Product dimensions
The appropriate quantity required of shampoo and shower gel was identified initially through
surveys and market research. Subsequently, many variations in product dimension were
computed and the following size was found to be most the optimum.
110 mm X 90 mm
This size of the sachet holds 30 ml of shower gel and 30 ml of shampoo.
Total net product volume – 60 ml.
3.4.1 Material Selection based on forming design
Due to the unique forming technique of the two way spout sachet there were necessary
alterations required to the existing structures.
Through research it was found that in order to seal the sachet, the front and back layer of the
film has to be same. Consequently two possible structures were identified.
1. PE / PET / VMPET / PE
2. HSPET / VMPET / HSPET
First configuration
● PE would act as a sealing layer as well printing layer. The thickness of PE would be 40
micron.
● PET layer would act as a barrier layer as well as provide integrity. The thickness of PET
layer would be 12 micron.
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light resistant products. The thickness of VMPET would be 12 micron.
● PE would act as a sealing layer as well printing layer. The thickness of PE would be 40
micron.
● The total thickness of this structure would be 104 micron.
● Using the existing structural design which is been already been tested and widely
accepted in the industry, Adding a PE layer at the top does not affect the integrity of the
sachet and also does not chemically react with the product filled inside.
● The problem with this structure is that PE does not have excellent printing
characteristics as a result the printing done on PE would have a hazy appearance. Which
won’t be desired as it is a body care product. The issue of hazy appearance can be
resolved graphics.
Second configuration
● HSPET would act as a sealing layer as well as a printing layer. The thickness this layer
would be 25 micron.
light resistant products. The thickness of this layer would be 12 micron.
● HSPET would act as a sealing layer as well as a printing layer. The thickness this layer
would be 25 micron.
● The total thickness of this structure would be 62 microns.
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First configuration vs Second configuration
Table 3.2 First configuration vs second configuration
Properties 1. PE / PET / 1. HSPET / VMPET

VMPET / PE / HSPET
Sealability Excellent Excellent
Mechanical properties Good Excellent
Odor resistance High High
Dimensional Stability in Good Excellent

high Temperature
Film Thickness 80 – 105 micron 50 – 65 micron
Printability Poor Printability Hazy Excellent printability

effect
Sealing temperature 130 °C 100 -160 °C
Considering excellent printability and compatibility of the material with product, And also
considering sustainable side of using a lesser micron material in manufacturing of sachet. Since
using a HSPET structure would increase the recyclability of the sachet. And other advantages
over the first structure as depicted in the table 3.2. HSPET/VMPET/HSPET is chosen as the
appropriate structure for construction of the sachet.
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3.5 Manufacturing Feasibility
3.5.1 Vertical Form fill Sealing Machine
Figure 3.2 Custom VFFS machine
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Table 3.3 Annotations for custom VFFS machine
Stage No Annotations for VFFS machine

1. Roll is transformed into S shape by the former
2. Photo sensor which is in sync with print repeat length
3. Vertical sealers
4. Cooling
5. Perforating jaws
6. Sachet opening and filling
7-9. Spout placement and sealing
10. After rotation second side filling
11-13 Spout placement and sealing
Machine usually use a roll of single sheet material known as roll stock which is feed into the
machine at the feeding section, The roll is unwinded with the help of motors. As shown in the
above figure 3.2
2. In feed and Sachet forming
Material from a roll of a given web dimension is fed through a series of rollers to a bag forming
collar/tube which has 2 set of roller/positioner which forms a S shape in film that is passed
between the collar/tube .
The bag forming collar is a precision engineered component that receives the film web from
the rollers and changes the film travel from a flat plane and shapes it around a bag forming tube.
The design of the bag forming collar cab be engineered to get the optimum efficiency from
metalized materials, heavy paper laminates. As displayed in the above figure 3.2 at stage 1.
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3. Sealing and perforation
As the film gradually moves down the horizontal cross bar heat sealer, It seals the bottom of
the film and which the help of perforation knife and horizontal cross bar heat sealer, It seals and
perforates the film. Shown at stage 3 in above figure 3.2.
4. Film rotating unit
After sealing the film, with the help of an inclined idler roller film is rotated from vertical to
horizontal direction and send towards the filling unit.
5. Filling unit
At the filling unit, with the help of contact filling method. The liquid product is then dispensed
into each sachet by round tubes or flat nozzles which fills the product into the sachet.
6. Spout attachment
After filling the sachet is then send to a spouting unit where spout is attached to the sachet.
7. Sachet rotation
The sachet is then again rotated 180 degrees with help of idler rollers.
8. Second filling unit
At the filling unit, with the help of contact filling method. The liquid product is then dispensed
into each sachet by round tubes or flat nozzles which fills the product into the sachet.
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9. Second spout attachment
After filling the sachet is then send to a spouting unit where spout is attached to the sachet.
10. Collection
The filled spout sachets in roll form is collected at the end of the line.
Drawbacks of this method:
● More number of equipment’s and utilities are used.

● Time consuming.
● Complex manufacturing method.
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3.5.2 Horizontal form fill seal machine type 1 (Fully automated)
Figure 3.3 Custom HFFS machine type 1
38
Table 3.4 Annotations for Custom HFFS machine type 1
Stage no Annotations for figure Custom HFFS machine type 1

3. Vertical sealers
4. Cooling
5. Perforating jaws
12. Film rotation
13 Second side filling
14-17 Spout attachment and sealing
machine at the feeding section, The roll is unwinded with the help of motors. Shown in the
figure 3.3.
+accordingly. As displayed in the above figure 3.3.
3. In feed Sachet forming
Material from a roll of a given web dimension is fed through a series of rollers to a bag-forming
collar/tube which has 2 set of roller / partitioner which forms a S shape in film that is passed
between the collar/tube. Depicted in the above figure 3.3 at stage 1.
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4. Vertical Sealing
5. Perforation of the Sachet
With the help of perforation jaws the pouches are separated into individual blanks.
6. Filling operation and spout attachment of first side
● Filling the pouch with the help of a nozzle (contact filling) and then attaching a spout
to it with the help of spout sealer.
● Attaching the spout to the pouch and sealing the spout and then the product is filled into
the pouch through the nozzle.
7. Sachet rotation
The sachet is then again rotated 180 degrees with help of idler rollers.
8. Filling and spouting of second side
It is exactly same as the first side filling and spouting.
9. Collection
The filled spout sachets in roll form are collected at the end of the line.
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3.5.3 Horizontal form fill seal machine type 2 (Semi-automatic)
Figure 3.4 Custom HFFS machine Semi-automatic

41
Table 3.5 Annotations for Custom HFFS machine type 2
Stage no Annotations for figure custom HFFS machine type 2

3. Vertical sealers
4. Cooling
5. Perforating jaws
7-11. Spout placement and sealing
12. Manually removing and resetting at the second station, second side filling
machine at the feeding section, The roll is unwinded with the help of motors. As shown in the
figure 3.4.
accordingly. Depicted in the above figure 3.4.
3. In feed Sachet forming
between the collar/tube. As shown in first stage of figure 3.4 at stage 1.
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4. Vertical Sealing
5. Perforation of the Sachet
With the help of perforation jaws the pouches are separated into individual blanks.
6. Filling operation and spout attachment of first side
● Filling the pouch with shampoo the help of a nozzle (contact filling) and then attaching
a spout to it with the help of spout sealer.
● The entire roll is collected and winded at end of filling line.
7. Loading of the sachet upside down in different filling unit
The film is loaded upside down in an filling unit such a way that, The unfilled side is at the top.
8. Filling and spouting of second side
It is exactly same as the first side filling and spouting.
9. Collection
The filled spout sachets in roll form are collected at the end of the line.
Drawback: A time consuming process.
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3.5.4 Horizontal form fill seal machine type 3 (Manual filling)
Figure 3.5 Custom HFFS machine type 3 Manual filing
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Table 3.6 Annotations for custom HFFS machine type 3
Stage no Annotations for HFFS machine type 3

3. Vertical sealers
4. Cooling
5. Cutting
6-10 Spout attachment
12. Air flushing
13. Manually filling one side
14. Air flushing
15. Second side manual filling
machine at the feeding section, The roll is unwinded with the help of motors. Shown in the
figure 3.5.
accordingly. Depicted in the above figure 3.5.
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3. Infeed Sachet forming
between the collar/tube. Shown in the first stage of the figure 3.5.
4. Vertical Sealing
5. Spouting
The spout is attached at the top and bottom opening.
6. Cutting to Individual Sachets
With the help of cutting jaws the pouches are separated into invidual blanks.
7. Filling the first side of sachet
First opening is manually filled with the help of a manual filling machine through the spout.
8. Filling the second side of sachet
Second opening is manually filled with the help of a manual filling machine through the spout.
9. Collection
Each individual sachet are unitized inside corrugated fiber board carton in the form of units.
46
Advantage:
● Reduces the complexity of the process.

● Most basic process
Disadvantage: Time consuming.
Comparative Study between all configurations
Table 3.7 Comparative study of all the 4 configurations
Properties and Vffs machine Hffs machine Hffs machine Hffs machine
feasibility single line double filling line with manual
filling
Time Least Low High Highest

Consumed/Cycle
Time
Equipment Used Highest High Low Least
Efficiency of High Highest Low Least

process
Intermediate Idler Required Not required Not required Not required

roller
Complexity Highest High Low Least
47
3.6 Costing
Materials required for sachet roll HSPET, VMPET, Spout, Adhesives
1. HSPET
Density – 1.4g /cc
Film thickness required 25 microns
1 1
𝑦𝑖𝑒𝑙𝑑 = =
ρT 1400 × 25 × 10‾⁶
Yield = 28.57 m2/ kg
2. VMPET
Density – 1.4g /cc
Film Thickness required- 12 microns
1 1
𝑦𝑖𝑒𝑙𝑑 = =
ρT 1400 × 12 × 10‾⁶
Yield = 59 m2/ kg
3. Area for 1 sachet = 35cm × 10 cm
= 0.035 m2
4. Configuration selected HSPET-VMPET-HSPET
48
5. Area of HSPET for 1 lakh sachet
= 2 × Area of 1 sachet × 100000
= 7000 m2 + 10 % wastage
= 7700 m2
6. Weight of HSPET for 1 lakh sachets = 269.51 kg
7. Area of VMPET for 1 lakh
= 0.035 × 100000
= 3500 + 10 % wastage
= 3850 m2
8. Weight of VMPET required for 1 lakh sachets = 134.75 kg
9. Cost of 1 kg HSPET and VMPET = Rs 150
10. Weight of HSPET and VMPET = 269.5 + 134.75
= 404.26 kg
11. Cost of HSPET and VMPET
= 404.26 x 150
= Rs 60,639
49
12. Assuming Tie layer required is 2gsm for the roll
Tie layer required for sachet forming = 7.7 kg
Cost of 1 kg lamination adhesive - Rs 400
13. Cost of 7.7 Kg adhesive - Rs 3080
14. Spout cost = 15paise / piece
Cost of 2,02,000 spouts
= Rs 0.15 × 2,02,000
= Rs 30,300
15. Total Raw Material Cost
Cost of roll + cost of adhesive + cost of spout
= 60,693 + 3080 + 30,300
= Rs 94,073
16. Machinery Required
1. Manual Filling Machine - Rs 5 Lakh
2. Forming Machine - Rs 10 Lakh
3. Total Machinery Cost – Rs 15 Lakh
50
17. Production
Cycle Time
One sachet – 7 seconds
Total - 8.571 sachets / min
Shifts
2 shifts a day - 8 hours per shift
=14 working hours (break excluded)
Total Production = 8.571 x 60 x 14
= 7200 sachets / day
Monthly Production = 187200 sachets
Workers Required - 7
Wages = 2 x 7 x 500
= Rs 7000
Total cost for production of 1 sachet – Rs 1 approximately
Table 3.8 Summary of costing
Sr no. Costing element Quantity Price

1. Roll 404.26 kg Rs 60,639
2. Adhesive ( Tie layer ) 7.7 kg Rs 3080
3. Spout 2,02,000 pieces Rs 30,300
4. Total raw material cost Sum of 1,2,3 Rs 94,073
5. Manual filling machine 1 Rs 5,00,000
6. Forming machine 1 Rs 1,00,000
51
Chapter 4
Result and Discussion
4.1 Prototype development

The concept was generated using a paper where the shape and forming style of the package
was determined.
Then the prototype was made using the multilayer laminated films. The problem which was
identified when using the conventional layer of multilayer films used in making sachet and
spout pouches was the issue with sealing of film.
So the material was determined by different study and material selection was done according
to the machining technique and forming design.
The forming method and the machine feasibility was identified .First looking at the structure
of the package, VFFS machine and filling machine was identified as the ideal machine for
making the package. Then the package was made using the HFFS machine using a single
inline machine. The most suitable method identified was manual filling machine.
Problems that were encountered:
 When convention multilayer film was used, there was an issue with sealing of the
package.
 When thick multilayer film was used there was an issue with sealing.
 Initially the determining the size and dimension of the film was issue.
Advantages
 Having sachets as small portion packages are very cost-effective and pocket-friendly. For
the companies introducing their products in sachets, it becomes an important cost-
cutting tool that maximizes the sale and reduces packaging cost. The sale gains weight
since the consumer who does not want to purchase bigger portions will tend to buy
smaller portions and that too in a pocket-friendly manner.
 Handling and carrying sachets are far easier than carrying the larger portion packs.
Shampoos, Shower gel and many more come in bigger bottled packs. They can't be
carried while travelling or for short trips. Instead, it becomes much easier and
convenient when the same thing gets handy as smaller portion packs.in the form of a
sachet.
 Simple packaging allows the contents of the sachets to be used and the packet thrown
easily. While the similar things coming in glass bottles or bigger packs have to be carried
during travelling until you find the proper disposal bin or site.
52
 The sachets are sealed from three or four sides. This makes them leak-proof and you can
keep them safely anywhere without having worried about the contents getting leaked.
While the larger portion bottled packs tend to leak from the top of the bottle gets turned
upside down in a luggage bag while travelling contaminating other accompaniments.
 Small sachets have enhanced the aesthetics and are more presentable.
Disadvantage:
 Increases the amount of single use plastics that will be used.

 The process for making this kind of package is complex and time consuming.
Following prototype was made
Figure 4.1 Prototype
Specifications of the above figure are
Dimension - 110 mm X 90 mm
Material structure – MPET / PE
Thickness of the film – 40 micron.
53
Chapter 5
Summary and Conclusion
5.1 Summary
Sachets have played quite a role in mobilizing FMCG products in India. Sachets have now.
Become popular in the skincare and hair care segment. Sachets make up for more than 75
percent of the total volume of the shampoo segment. Shower gel as product has been around
the market, yet restricted to a particular segment the shower gels came in plastic rigid containers
and found it difficult to augment the soap market. This project has attempted to create a new
travel friendly pack for shampoo and shower gel in a two way spout sachet. The design of the
sachet is made in such a way that to increase the convenience for customer to carry shampoo
and shower gel. This design will prompt the customer buying a shampoo sachet to try the dual
pack. This could lead to an increase in the trails and usage of shower gels. It also would be
economic pack, It also would eliminate the need of rigid container for shower gel. The package
forming technique might also help in the reduction of carbon footprint.
As the package was made using concept generate study about the material and process was
done.
 The forming technique for the twin spout package was identified
 The material selection was done according to forming technique.
 The machine feasibility and proof of concept was checked.
 Cost estimation for creating a single package was identified.
54
5.2 Conclusion
 S shaped. Creating a unique design for the package providing to fit spout at both ends.
 As the design of package is S-shape has to have sealing and printing ability on both the
side of the package. The material for film used is HSPET/VMPET/HSPET.
 According to the feasibility 2 forming and filling technique can be used, HFFS machine
with an inline filling unit can be used when the process has to be in garland form. And
if it has to in a single unit form the HFFS machine can be used with a manual filling
technique.
 The cost estimate for creating a single package was found to 1 rupee. Which makes it
cost effective.
 The package dimension is 110mm X 90mm and can store 30 ml of shampoo and 30 ml
of shower gel.
 The design for the same is to be patented.
5.3 Future scope for work.

Future scope of the project is to create a working prototype on a commercial scale machine and
work towards automation of the whole process. Find a more sustainable material of construction
for the sachet. Filing for a patent on design. Offering other product variants in pack form eg
Shampoo - Conditioner, Face cream - Body cream, Sweet sauce - Hot sauce.
55
References
1. Yam, K. (2010). The Wiley Encyclopedia of Packaging Technology. New York, NY: John
Wiley & Sons.
2. Hanlon, J., Kelsey, R. and Forcinio, H. (1998). Handbook of package engineering.
3. F. A. Paine - The Packaging User’s Handbook (1990, Springer US)
4. John R. Wagner Jr. - Multilayer Flexible Packaging_ Technology and Applications for the
Food, Personal Care, and Over-the-Counter Pharmaceutical Industries (Plastics Design
Library) (2009)
5. W. Soroka,- Fundamentals of Packaging Technology
6. Thomas Dunn, Manufacturing flexible packaging _ materials, machinery, and techniques-

William Andrew Publishing, , Elsevier Inc (2015), 3rd Ed.,
7. (Plastics Design Library) Barry A Morris, the Science and Technology of Flexible
Packaging. Multilayer Films from Resin and Process to End Use, William Andrew (2017)
8. Athalye A S, - Handbook of Packaging-Plastics, Multi-Tech Publishing Company, 1999
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“To Design A Two Way Spout Sachet For Shampoo And

Submitted in partial fulfillment of the requirements

Printing & Packaging Technology

Anurag Ganapathi 116A4002

Ishwar Shenoy 116A4019

Vishal Manikandan 116A4026

Under the Guidance of:

Prof. Prasad Balan Iyer

Department of Printing & Packaging Technology

SIES Graduate School of Technology

following students, submitted to the University of Mumbai in partial

fulfillment of the requirement for the award of the degree of Bachelor

of Engineering in Printing & Packaging Technology.

Anurag Ganapathi 116A4002

Prof. Prasad Balan Iyer Dr. A. N. Kemkar

shampoo and shower gel” by following students done at SIES –

Graduate School of Technology, Nerul is approved for the degree of

Bachelor of Engineering in Printing & Packaging Technology.

Anurag Ganapathi 116A4002

Name of External Examiner: --------------------------------

Name of Internal Examiner: --------------------------------

Place: Nerul, Navi Mumbai

Anurag Ganapathi 116A4002 _____________

K Nishant 116A4009 _____________

Ishwar Shenoy 116A4019 _____________

Vishal Manikandan 116A4026 _____________

Figure Figure Caption Page

Table Table Caption Page

The object of the project is to

e. Offering other product variants in pack form.

2.1 On basis of existing structure

Figure 2.1 Existing laminate structure

Based on the figure 2.1 Material property

Advantages of using PET on the outside

● Excellent Printing Characteristics and finish

Thickness range – 10 – 12 microns

Thickness of film used - 10 – 12 microns.

Table 2.1 Data sheet for VMPET

Advantage of using PE as sealing layer

● High seal strength.

Thickness of film used – 20 to 50 microns.

2.2.1 Vertical Form fill Sealing Machine

1. Film unwind and transport

Figure 2.2 Unwind section of VFFS machine

2. Optional Printing section

Figure 2.3 Film Tensioning and Positioning unit

4. Film Cutting & Folding

6. Sachet Sealing and Filling

2.1.2 Formation of Spout pouch by Horizontal form fill seal machine

Figure 2.4 HFFS Machine

2. Film tensioning and positioning

5. Cutting of the pouch

6. Filling operation and spout attachment

There are two types of filling operations identified

2.3 Material Selection based on unique forming design

In the first configuration

● PE would act as a sealing layer as well printing layer.

● HSPET would act as a sealing layer as well as a printing layer

Figure 2.5 HSPET Structure