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Flexible packaging systems with the highest line efficiency for single-serve packets

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Perfectly dispensed single-serve packets are practical and are enjoying increasing popularity, especially for fast coffee preparation. Compostable capsules made of paper, for example, and single-serve aluminum packs are becoming increasingly popular, although plastic capsules continue to lead in some markets. No matter which material your customers prefer or whether you want to manufacture single-serve packets with tea, nutritional supplements or liquid concentrate instead of coffee capsules, Optima will supply you with highly efficient and flexible standalone machines as well as high-performance turnkey systems.

100 years of expertise Full aroma. Maximum efficiency

Consumers are increasingly demanding sustainability, especially in the single-serve packaging sector. In addition, consumers like to have a choice between different packaging sizes. As a manufacturer, you have to meet these demands and at the same time face increasing cost pressures. That's a balancing act you can easily manage with Optima as your partner: Countless successful solutions for start-ups to major corporations attest to it!

The precise weighing and filling of valuable and sensitive products has been our passion for 100 years. We bring this incalculable wealth of experience to every single-serve application. Whether you want to fill capsules with fine powder, granulate or liquid, Optima will provide you with core processes tailored to your needs from a single source – from a standalone machine to a complete line, including filling, boxing, tray packaging and palletized options.

Capsules product group
100 years of expertise Full aroma. Maximum efficiency

Consumers are increasingly demanding sustainability, especially in the single-serve packaging sector. In addition, consumers like to have a choice between different packaging sizes. As a manufacturer, you have to meet these demands and at the same time face increasing cost pressures. That's a balancing act you can easily manage with Optima as your partner: Countless successful solutions for start-ups to major corporations attest to it!

The precise weighing and filling of valuable and sensitive products has been our passion for 100 years. We bring this incalculable wealth of experience to every single-serve application. Whether you want to fill capsules with fine powder, granulate or liquid, Optima will provide you with core processes tailored to your needs from a single source – from a standalone machine to a complete line, including filling, boxing, tray packaging and palletized options.

Capsules product group
You can count on it

Customized machine solutions with major advantages

With your experience and our expertise, we will develop together perfect technologies tailored to your special requirements. What’s in it for you:

  • Maximum format flexibility for capsules (focus on capsule type) and packaging
  • Maximum system availability
  • A variety of setting patterns without changeover times
  • No product loss thanks to inline quality testing
  • Maximum automation for faster production
  • Output rates depending on the requirements profile: 100 to 2,000 capsules per minute
Every item is perfect

Single-serve packets that your customers will love

Liquid, powder or granule form – your product and requirements will determine the single-serve packaging. They are the benchmark for the entire process. For the best results and outstanding in-cup quality:

  • Precise dosing
  • Gentle product handling
  • Reliable product protection 
  • Preservation of all the aromas 
In close collaboration with you, we will develop the perfect single-serve solution for your product. Whether compostable capsules, aluminum and plastic capsules, or pods.
Aluminum coffee capsules
Coffee capsules
Sustainable coffee capsules
Coffee capsules
Portrait Christoph Held
Christoph Held, Managing Director, OPTIMA consumer GmbH

Listening is one of our greatest strengths. We take on board customers' experience, and turn them into a perfect customer-specific solution with them. That's how we achieve the best results.

Christoph Held, Managing Director, OPTIMA consumer GmbH
Efficient step-by-step capsule filling and packaging
Efficient step-by-step capsule filling and packaging
Machine solutioin for capsules
1. Loading capsules
2. Precise dosing
3. Punching and sealing
4. Grouping capsules
5. Boxing
6. Tray packaging
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Machine solutioin for capsules
1. Loading capsules
Automatic loading, machine portion packing

Pre-fabricated capsules are fed manually out of the box or by autoloader as needed. It doesn't matter whether the capsules are aluminum, plastic or compostable. Then the empty boxes are returned and stacked.

  • Fully automated process
  • Gentle handling
  • Easy removal of empty boxes 
2. Precise dosing
Portion packing machine for coffee - process dosing

We use the appropriate dosing technology depending on whether you want to fill up with powder, granules, liquid or flavorings. Solids can be gently compressed without changing product quality. The filling process in a controlled atmosphere ensures reduced oxygen levels. One hundred percent weighing guarantees continual self-optimization of the filling weight. Fluctuations in bulk density are immediately detected and corrected.

  • Precise dosing (in mg and ml)
  • Reduction of product loss
  • Clean capsule edges
  • Tool-free format changes
  • Easy exchange of parts in contact with the product
  • Integrated product compression
3. Punching and sealing
Machine for portion packing of coffee capsules - process punching and sealing

You can also be flexible with the material for lids: Our system processes laminates, aluminum foil, paper or filter materials from a stack or roll. Foil-saving modules ensure optimum use of material. Lids are securely sealed using thermal sealing, induction or ultrasound.

  • Ceramic insulation with extremely high temperature accuracy
  • 100% capsule leak test inline
  • Exact lid positioning
  • Optimized material use, very high level of material exploitation
4. Grouping capsules
Machine for portion packing of coffee capsules - process grouping

One of our most important innovations is the patented gap closer. It allows any setting pattern to be generated and the desired number to be dispensed. Every capsule has its own controllable shuttle so that the correct number of units is continuously conveyed to the correct place for the boxing machine. The best part: The system does not require a format change for a setting pattern thanks to the state-of-the-art linear motor system that reduces the footprint for the entire system as well. A format change of about 15 minutes is only required for changes to the final packaging.

  • Flexible grouping
  • Any setting pattern without format change
  • Format flexibility
  • Inline controls (flap control, weight control, vacuum control)
5. Boxing
Machine for portion packaging of coffee capsules - cartoning process

Our systems erect the selected box flat blanks. The toploader carefully picks up the pre-grouped capsules and sets them into the packet – each rotated or not rotated, depending on the pattern. To separate the capsule layers, intermediary layers and or punched intermediary layers that secure the capsules can be inserted. If a box does not meet the high quality standards, the whole box is rejected; the good capsules can be returned and repackaged.

  • Flexible box format: change in only 15 minutes
  • Setting pattern as required without format change
  • Inline laser marking of the secondary packaging
  • Integrated check weigher
  • Automatic insertion of different intermediate layers
6. Tray packaging
Machine for portion packaging of coffee capsules - process tray packing

The filled boxes are grouped according to your requirements and packed in trays. While doing this, we pay attention to space-saving feed technology adapted to your production space as well as efficient shapes of the trays. One-item and two-item trays marked and labeled inline are possible.

  • Wrap-around tray and tray lid solution
  • Wide-ranging grouping variants
  • Integrated systems for product labeling and tracking
Sieghardt Lay
Do you have questions about our systems and turnkey solutions for portion packs or would you like to discuss your special requirements with us?
Sieghardt Lay
Director Sales Single Serve Solutions
+49 791 94606-3105 customer.info@optima-packaging.comWrite e-mail
Sieghardt Lay
Sieghardt Lay
Director Sales Single Serve Solutions
Highly flexible and extremely efficient with the very low material consumption
Turnkey expertise in producing beverage capsules

Do you want to manufacture single-serve packets efficiently and with the highest quality standards? Do you want your system designed according to your requirements and have in the end the greatest flexibility in cartoning? We will be happy to help: At Optima, you have a single point of contact for your entire production line. Your requirements be met, and you will benefit from integrated interfaces and a minimum footprint.

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Line competence

Key Facts
Line solution for filling and packaging of beverage capsules
Capsule filling machine

Efficiency all along the line: maximum setting pattern flexibility without format changes with the OPTIMA CBF cartoner

Marleen Winkelaar, Manager Innovation, R&D at Ahold Delhaize Coffee Company

Although Optima was confronted during the course of the project with several challenges, for example, the conversion to aluminum capsules, the staff did their best to keep the project on track and always weighed up all possible options. 

Marleen Winkelaar, Manager Innovation, R&D at Ahold Delhaize Coffee Company
Single serve solutionSingle serve solution
OPTIMA CFL Filling and closing capsules with a small footprint Output: 100 - 2,000 capsules per minute

The OPTIMA CFL is a flexible filling and closing system for single-serve packets made from a range of different materials. It is available in various versions, from an entry-level model to a high-performance solution with an output of 2,000 capsules per minute. But no matter which CFL you choose, your production will protect the environment and save resources thanks to optimized foil utilization, very high dosing accuracy, reduced gas consumption and extremely low energy consumption.

Single serve solution OPTIMA CFL1
OPTIMA CFL1

The compact one

With the compact CFL1, you will produce up to 360 capsules per minute

Single serve solution OPTIMA CFL10
OPTIMA CFL10

If you need a little more

The CFL 10 processes up to 780 capsules per minute

Single serve solution OPTIMA CFL40
OPTIMA CFL40

The high-speed solution

The CFL40 processes up 2,000 capsules per minute

Major advantages
The OPTIMA CFL will guarantee you
Maximum machine efficiency
Very high material exploitation
Flexibility: aluminum, plastic and compostable capsules
Safe gassing with minimized gas consumption
Expandable modular design for future adjustments
Vertical start-up for direct production with highest efficiency
Cartoning solution for capsulesCartoning solution for capsules
OPTIMA CBF A boxing machine for a wide range of setting patterns without format changes Output: up to 250 boxes/minute

The OPTIMA CBF high-performance boxing machine offers maximum setting pattern flexibility and can be switched to other box sizes in no time at all. This is made possible by its state-of-the-art linear motor system that reduces the footprint of the entire production line.

Each capsule has its own controllable shuttle that facilitates individual groupings. This always allows exactly the desired number of capsules to be conveyed to the boxing machine.

Demonstrably efficient
The OPTIMA CBF offers you
A minimized footprint
Capsule groupings as required without a format change
Gentle handling of the capsules due to integrated robotics
Integrated check weigher
Integrated space-saving control cabinets
Low energy consumption due to vacuum switch-off
Case packer for boxesCase packer for boxes
OPTIMA TMF A case packer for maximum efficiency inline Output: up to 15 trays/minute

The OPTIMA TMF casepacker pre-groups the boxes from the OPTIMA CBF and then packages them in one-item or two-item trays. The trays are labeled and marked inline. Developed for integration into production lines, the OPTIMA TMF works perfectly with other machines in the line.

Powerful performance

The OPTIMA TMF packs

One-item and/or two-item trays
Very large format range 
Integrated labeling module
OPTIMA CFROPTIMA CFR
OPTIMA CFR The efficient compact solution for a fast entry level Output: up to 220 capsules/minute

Whether new on the market or contract filler, the OPTIMA CFR will give you a decisive edge: Thanks to its modular, configurable design, it can have production up and running in just a few months so that you can quickly and safely get capsules to the point of sale. It also takes up little space, because the control cabinet is built-in. The "balcony design" provides optimum accessibility and makes cleaning and maintenance easier. The required functional units can arranged how you want.

Many advantages in minimal space

With the OPTIMA CFR, you will benefit from

Fast delivery time
Very good accessibility
Easy cleaning, maintenance and operation
Plastic, aluminum and compostable capsules
Modular and configurable
Minimal space required thanks to the built-in control cabinet
Helmut Jakolat, Head of Production Engineering, HERMES Pharmaceuticals

Cooperation with Optima was outstanding. The installers were real experts and well prepared. They set up the system within two days. So we could perform test runs and train operators.

Helmut Jakolat, Head of Production Engineering, HERMES Pharmaceuticals
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OPTIMA CFR – Capsule filler rotary

Key Facts
THE COMPACT to start with - flexible, quickly available and efficient
Sieghardt Lay
Do you have questions about our systems and turnkey solutions or would you like to discuss your special requirements with us?
Sieghardt Lay
Director Sales Single Serve Solutions
Sieghardt Lay
Sieghardt Lay
Director Sales Single Serve Solutions
+49 791 94606-3105 Write e-mail
Success stories about single-serve packaging – by and with OPTIMA
Sieghardt Lay
Do you have questions about our systems and turnkey solutions for portion packs or would you like to discuss your special requirements with us?
Sieghardt Lay
Director Sales Single Serve Solutions
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