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Baby milk is a highly sensitive product. It should provide the baby with all the important nutrients it needs and protect its immune system in the first few months of life. The prerequisite for this is high-quality infant formula, which is produced and filled in compliance with the strictest hygiene and quality standards. We have over 50 years of experience of developing and building filling and packaging systems for infant formula, and we can supply you with machine solutions that are a recipe for success.
Service and synergies How you can benefit from our infant formula expertise
As a manufacturer of powdered infant formula, you face multiple challenges. Infant formula needs to be produced and filled in a safe, hygienic way and at the same time, it is subject to growing pressure to reduce costs. In the market, there is a growing demand for sustainability, as well as a desire for powders and containers that can be adapted to suit a wide range of applications.
How do you go about meeting all these demands? Choose a recipe for success that will stand up to today's and tomorrow's demands. With core processes tailored to meet your needs, Optima offers the very heart of your production line from a single source, and implements both individual machines and turnkey solutions with all process steps.
You will benefit from synergies within the Optima group of companies. At Optima Pharma, for example, we work in accordance with the strict filling standards required for pharmaceuticals. We also use this expertise to create machine solutions for your infant formula. This guarantees you safe processes and means you can rely on Optima's systems expertise and experience with confidence.
Service and synergies How you can benefit from our infant formula expertise
As a manufacturer of powdered infant formula, you face multiple challenges. Infant formula needs to be produced and filled in a safe, hygienic way and at the same time, it is subject to growing pressure to reduce costs. In the market, there is a growing demand for sustainability, as well as a desire for powders and containers that can be adapted to suit a wide range of applications.
How do you go about meeting all these demands? Choose a recipe for success that will stand up to today's and tomorrow's demands. With core processes tailored to meet your needs, Optima offers the very heart of your production line from a single source, and implements both individual machines and turnkey solutions with all process steps.
You will benefit from synergies within the Optima group of companies. At Optima Pharma, for example, we work in accordance with the strict filling standards required for pharmaceuticals. We also use this expertise to create machine solutions for your infant formula. This guarantees you safe processes and means you can rely on Optima's systems expertise and experience with confidence.
More than just filling: You can now realize the full range of infant formula packaging using Optima's filling and packaging equipment, for example, metal cans, containers, cardboard boxes and single serve applications in both capsule and tablet form.
Do you have questions about our plants and turnkey solutions for baby milk powder or would you like to discuss your special requirements with us?
Kai Brunner
Director Sales Powder Milk Formula
+49 791 94606-3284 customer.info@optima-packaging.comWrite e-mail
Kai Brunner
Director Sales Powder Milk Formula
Targeted experimental setups rather than trial and error
We use informative pre-tests to help you get the most out of your filling system. In these filling tests, we use ramming tests, for example, to establish how compactable your products are. By knowing this, we can determine the amplitude for the vibration. This eliminates powder domes and ensures perfect close for your containers.
We also use gassing tests to ensure that there is an optimal level of residual oxygen in the filled product or containers. This is achieved particularly accurately by the OPTIMA EGS evacuation, gassing and seaming system with several vacuum stages – and it also saves on gas.
- Avoiding product degradation and loss
- Calculating filling speed
- Calculating maximum output
- Specifying the residual oxygen value per product
Targeted experimental setups rather than trial and error
We use informative pre-tests to help you get the most out of your filling system. In these filling tests, we use ramming tests, for example, to establish how compactable your products are. By knowing this, we can determine the amplitude for the vibration. This eliminates powder domes and ensures perfect close for your containers.
We also use gassing tests to ensure that there is an optimal level of residual oxygen in the filled product or containers. This is achieved particularly accurately by the OPTIMA EGS evacuation, gassing and seaming system with several vacuum stages – and it also saves on gas.
- Avoiding product degradation and loss
- Calculating filling speed
- Calculating maximum output
- Specifying the residual oxygen value per product
Seeing the big picture thanks to digital twinning
We use digital twins and simulations to check the level of operating requirements for your system, and determine parameters such as the autonomy time as well as its behavior under specific environmental conditions. This all has one goal: to achieve the highest possible OEE (Overall Equipment Efficiency) for you.
- Optimizing the utilization of operating staff on the line
- Analyzing microstops and strategically placing buffer tables to increase OEE
- Identifying and eliminating bottlenecks in the entire line
- Early line planning
Seeing the big picture thanks to digital twinning
We use digital twins and simulations to check the level of operating requirements for your system, and determine parameters such as the autonomy time as well as its behavior under specific environmental conditions. This all has one goal: to achieve the highest possible OEE (Overall Equipment Efficiency) for you.
- Optimizing the utilization of operating staff on the line
- Analyzing microstops and strategically placing buffer tables to increase OEE
- Identifying and eliminating bottlenecks in the entire line
- Early line planning
Testing and experiencing digital innovations
Either for standalone machines or lines, with design reviews in our Digital Innovation Center, you can keep an eye on your project throughout its entire development. Working together, we can check machine details long before your system is complete, plan logistics routes and easily and flexibly make changes to the overall system.
- Best possible ergonomics and ease of use
- Identifying change requests early on
- Improving system accessibility
Testing and experiencing digital innovations
Either for standalone machines or lines, with design reviews in our Digital Innovation Center, you can keep an eye on your project throughout its entire development. Working together, we can check machine details long before your system is complete, plan logistics routes and easily and flexibly make changes to the overall system.
- Best possible ergonomics and ease of use
- Identifying change requests early on
- Improving system accessibility
Your needs, our benefits
Smart ideas for your production – safe, profitable and resource-saving
Listening, thinking ahead, implementing: We have been working in close partnership with customers around the world in line with this principle for over 100 years. This means that you benefit from our product-specific application experience and from systems that are tailor-made to meet your exact requirements. The goal is clear: You want to have your products filled as safely, economically and as environmentally friendly as possible.
With no compromises
Solutions for your safety
Clearly traceable processes and production data for each container, along with one hundred percent in-process monitoring, ensure that your products meet the highest possible quality standards.
- Highest product quality and safety
- A one-stop shop for all sensitive high-care functionalities
- Minimum constant residual oxygen values
- Long shelf life for your products
- Optimal product protection in the closing process
Efficient manufacturing
Designed for economic efficiency
Your system arrives already fully tested at your premises. This keeps the time required and the cost of on-site commissioning to a minimum. Another bonus is the minimal high-care footprint. Line simulations ensure that you end up with the exact solution you need ahead of time – with a minimal footprint.
- Optimal performance for your entire system
- High availability of systems
- Harmonized interfaces
- Standardized processes for custom solutions
Saving resources
Packaging machines that are green at heart
We are already sustainably building the machines of tomorrow today. As a result, the unique combination of the three functions of evacuation, gassing and seaming on a single system leads to maximum output with a minimum footprint. In addition, you save investment costs for the clincher as well as operating costs – and also gain space plus production reliability.
- A small footprint in the high-care sector
- Reduced media consumption
- Minimized waste
Sustainable packaging
Rethinking the development of packaging
Supplying you with sustainable machines is one thing. However, it is also important to support you in developing sustainable packaging. After all, well-made packaging both extends food shelf life and eliminates waste. In doing so, we not only think sustainably, we also work that way.
Benefit from our "We care for tomorrow" strategy
Kai Brunner, Sales Director Powder Milk Formula, OPTIMA consumer GmbH
Our solutions for filling infant formula are about maximum safety and the highest possible production and resource efficiency.
Kai Brunner, Sales Director Powder Milk Formula, OPTIMA consumer GmbH
Packaging infant formula – step by step
Packaging infant formula – step by step
1. Filling
2. Evacuating, gassing, seaming
3. Putting the cap on it
1. Filling
Whether the containers are round, oval, rectangular or square, nothing can go wrong when filling infant formula. To ensure nothing does, the OPTIMA FS integrated auger dosers operate continuously, regardless of the types and shapes of material used. You can either fill based on the average value or ensure extremely precise dosage using the minimum quantity filling principle. The built-in topping-up system assists with this.
- Accurate dosing by weight
- High output of up to 320 cpm (cans per minute)
- Minimum give-away when filling according to the prepackaging order or with minimum filling
- An audit trail makes quality assurance easier
2. Evacuating, gassing, seaming
In this step, all three functions – evacuation, gassing and seaming – are combined and accommodated in a small area. Developed specifically for the infant formula market, the OPTIMA EGS system can process every can individually without batch processing. The entire product column is evacuated using the new evacuation process. You benefit from significantly reduced residual oxygen levels – even after several days. Another advantage is that there is no soiling of the flared rim.
- Reduced, compact footprint in the high-care area
- Individual evacuation and gassing alarms ensure distinct attribution
- Minimal residual oxygen levels (< 0.5 %) increase your products ‘shelf life
3. Putting the cap on it
Whether a snap-on or spoon-cap, with the OPTIMA Rotocap, your infant formula containers automatically get the right closure. The machine takes over the sorting, feeding and placing of the snap-on caps or the targeted positioning of the spoon cap.
- Camera recognition ensures alignment
- Cap applicator for all common closure types
Christoph Held – Managing Director OPTIMA consumer GmbH
One of the most important services we offer is listening – because we know the optimal solution can only be developed from an in-depth dialogue with our customers.
Christoph Held – Managing Director OPTIMA consumer GmbH
OPTIMA FS filling system More power for filling your infant formula
Output: up to 250 containers/min. | formats: Ø 70–156 mm
The OPTIMA FS combines portioning and filling power. The continuously operating machine with an integrated auger doser fills round, oval, rectangular and square containers made from a range of different materials. Use your topping-up system to produce based on the minimum quantity filling principle. For mean value filling (e-filling), simply use the filling system without topping up.
Feeding the containers into the filling star wheel. The OPTIMA FS fills containers of varying shapes and made of different materials.
The integrated auger doser means the infant formula is filled with high precision and minimal give-away.
The benefits for you
Easy access to parts that come into contact with the product
Hygienic design for thorough, easy cleaning
Downtime is reduced by fast, no-tool format changeovers
OPTIMA FS
Key Facts
A fact check for the filling line: How to optimally dose infant formula and fill it down to the exact gram
Download: Machine brochure OPTIMA FS
A fact check for the filling line: How to optimally dose infant formula and fill it down to the exact gram
We will send you the OPTIMA FS solution brochure. You will receive an e-mail with a download link.
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OPTIMA EGS evacuation, gassing and seaming system Packaging infant formula in a compact, efficient way
Output: up to 250 containers/min. | Format: Ø 70–153 mm
We have developed the OPTIMA EGS system specifically for the infant formula market. The system integrates the evacuation and gassing of your containers with a closing station provided by the customer – and does so with a much smaller footprint. In doing so, the system processes each can individually, without a batch process. Thanks to an innovative evacuation process, the EGS achieves lasting, greatly reduced residual oxygen levels.
The benefits for you
Reduced risk of imploding cans
An audit trail makes quality assurance easier
Reduced, compact footprint in the high-care area
Individual evacuation and gassing alarms ensure distinct attribution
Minimal residual oxygen levels (< 0.5 %) increase your products ‘shelf life
Managing director of an infant formula production plant
The OPTIMA EGS is an optimal custom system (…). Officially, residual oxygen levels are below one percent and therefore in a range that meets all the requirements for modern infant nutrition. In reality, however, the values in production are usually much lower than this.
Managing director of an infant formula production plant
Alongside core processes, Optima also provides other machine solutions for your infant formula manufacturing needs:
OPTIMA Rotocap closing machine Fully automatic closing solution
Output: up to 360 containers/min. I Format caps & containers: Ø 70–154 mm
The OPTIMA Rotocap capping machine is fully automated to process all common cap types, such as snap-on and spoon caps. Thanks to flexible linear motors, no format changeover is necessary if your cans or lids only vary in height. If you are planning to fit lids onto cans of different diameters, it takes just a few minutes to change over the format.
At 360 cans per minute, the continuous processing ensures smooth, rapid transfer. Individually servomotor-driven spindles ensure the lids are reliably positioned.
Cameras are available as an option to facilitate quality inspection and the alignment of caps with the containers.
The benefits for you
Rapid, tool-free change of format
Solution for snap and spoon caps
Option for parallel integration of different feeders (e.g., sorting and de-palletizing)
Easy to teach new container graphics/caps
Careful handling with no turning of the containers
Save on budget, time and stress Turnkey solutions let you get started
The bigger the production line, the greater the number of interfaces there are. These are known to be error-prone and costly to bridge. Why make the effort? When you choose us as your turnkey partner, you save on budget, time and stress. We take care of the subcontractors and scheduling so that your infant formula filling line can be up and running ahead of time. As a minimum, we will start up your core processes in advance, giving you a competitive edge in the light of rising market demands and shorter product lifecycles.
Turnkey plus point
Key performance features at a glance
Short start-up phase and time-to-market
Minimal space and cleaning requirements for high-care area
Standard interfaces make cross-manufacturer networking simple
You save time and money by commissioning your packaging line at Optima
A single contact for the entire process to reduce your project workload
Total systems with a service plan
You can count on this with turnkey solutions from OPTIMA
We support you throughout the entire lifecycle of your system to ensure long-term, smooth production. We are open to complementary technologies, and are happy to consult with your existing suppliers. We offer manufacturing intelligence solutions to make your production line even more profitable. When it comes to documentation, validation and project handling, you can benefit from our expertise in the pharmaceutical sector upon request.
- Reduced spare parts management (all machines from a single source)
- Reduced time and effort spent on training and troubleshooting with a standardized operating concept
Infant formula filling and packaging solutions
Key Facts
For your infant formula project: all the facts in a nutshell
Download: Key Facts Milk Powder
For your infant formula project: all the facts in a nutshell
We will send you the milk powder fact sheet. You will receive an e-mail with a download link.
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Are you looking for your own recipe for success in filling and packaging baby formula? Let's develop a solution that satisfies your big and small customers alike. We look forward to hearing from you.
Kai Brunner
Director Sales Powder Milk Formula
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