Customer Requirements

The customer needed to pack liquid ice pop products with the following main specifications:

• Product: Liquid ice pop / freezer pop

• Number of flavors: 5

• Filling volume: 90 ml

• Primary bag size: 48 × 260 mm

• Bag style: Four-side seal sachet

• Number of lanes: 10 lanes

• Machine speed: 25 cycles/min

• Estimated output: Up to approximately 250 individual ice pop sachets/min

• Packaging film: Composite laminated film

• Easy-tear notch: Included

• Power supply: 3 Phase, 220V, 60Hz

• Machine material: SUS304 stainless steel

In addition to the primary packaging process, the customer wanted the finished ice pops to be automatically counted and packed into larger secondary bags, minimizing manual collection and repacking.

Complete Packaging Line Solution

To meet this requirement, SAMFULL configured a complete production line consisting of:

1. Five Stainless Steel Storage Tanks for Five Flavors

The front end of the line is equipped with five independent stainless steel storage tanks, with each tank used for one ice pop flavor.

This allows the customer to prepare and store five different liquid formulations at the same time without mixing the products.

Each flavor is transferred independently to the filling system, making the line suitable for factories producing multiple SKUs or flavors.

The liquid feeding system also incorporates liquid level detection and automatic start/stop control, helping maintain a stable supply to the packaging machine.

The system includes dedicated CIP cleaning devices to simplify cleaning of the liquid-contact parts when changing flavors or carrying out routine sanitation.

2. SF-960-10 10-Lane Four-Side Seal Packaging Machine

The core machine is the SF-960-10 10-lane automatic liquid packaging machine.

It simultaneously forms, fills and seals ten narrow ice pop sachets during each packaging cycle.

Main configuration:

• 10-lane design

• Four-side sealing

• SUS304 stainless steel frame

• Siemens control system

• Liquid pump filling system

• 90 ml filling volume

• 48 mm bag width

• 260 mm bag length

• Approx. 5 mm longitudinal sealing width

• Approx. 6 mm top and bottom sealing width

• 96 mm film width per lane

• Approx. 960 mm total film width

• Laminated packaging film

• Easy-tear notch

• Static elimination device

• Color ribbon coding system

• English / Chinese touchscreen interface

With 10 lanes operating simultaneously at approximately 25 cycles per minute, the system can reach an output of around 250 individual ice pop sachets per minute, depending on the product characteristics and actual operating conditions.

3. Automatic Discharge and Counting System

After sealing and cutting, the finished individual ice pop sachets are discharged from the 10-lane machine and transferred automatically to the downstream system.

Instead of workers manually collecting and counting the sachets, an automatic counting system organizes the finished products according to the required quantity for secondary packaging.

This helps improve:

• Counting accuracy

• Production consistency

• Labor efficiency

• Connection between primary and secondary packaging

• Overall line automation

4. Secondary Pillow Bag Packaging

After counting, the grouped ice pops are automatically transferred into the secondary pillow packing machine.

The pillow packer packs multiple individual ice pop sachets together into one larger outer bag.

The complete packaging process therefore becomes:

5 Flavor Storage Tanks → Liquid Feeding → 10-Lane Ice Pop Filling & Four-Side Sealing → Discharge Conveyor → Automatic Counting → Grouping → Secondary Pillow Bag Packing

This configuration significantly reduces manual handling between the primary packaging machine and the final outer packaging process.

Why Use a Complete Automatic Line?

For high-output ice pop manufacturers, simply increasing the speed of the primary packaging machine is not enough.

When a 10-lane machine produces hundreds of sachets per minute, manual counting and secondary packing can quickly become the bottleneck of the entire production line.

By integrating the upstream liquid supply system and downstream counting and secondary packaging system, the customer can achieve a much more balanced production process.

Key advantages include:

• Five flavors can be handled with independent liquid storage

• High-speed 10-lane primary packaging

• Stable 90 ml filling

• Automatic counting instead of manual counting

• Automatic transfer between machines

• Secondary bulk bag packaging

• Reduced labor requirements

• Lower risk of counting errors

• Better production consistency

• Easier expansion of production capacity

• More suitable for continuous industrial production

Hygienic Design for Liquid Ice Pop Production

Because the product is a liquid food product, hygiene and cleaning were important considerations in the design.

The system uses stainless steel product-contact and machine structures and incorporates dedicated cleaning arrangements for the liquid feeding system.

Additional configuration includes a UV sterilization lamp and CIP cleaning system, helping the customer maintain cleaner production conditions and simplify routine maintenance.

From Five Flavors to Finished Multipacks

The main feature of this project is that it is not simply a 10-lane ice pop packaging machine.

It is a complete multi-flavor automatic packaging line integrating:

Storage + Liquid Feeding + Multi-Lane Filling + Sachet Packaging + Conveying + Counting + Secondary Packaging.

For ice pop, freezer pop and similar liquid products with multiple flavors and high production volumes, this type of integrated solution can significantly reduce the amount of manual work required after the primary packaging stage.

SAMFULL can customize the number of lanes, filling volume, bag dimensions, number of flavors, counting quantity and secondary packaging configuration according to each customer's production requirements.

Main Project Configuration