Built for the production line.
Custom mold design, thermoform tooling, machine retrofits, and spare-part supply for food, pharma, and industrial packaging lines.
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Packaging and handling machine concepts.
A selection from our machine concepts for packaging and food lines. Each was delivered as a layout, 3D model, process description and budget, so the client could decide before committing to a build.
Concept stage: 3D models and process layouts, not installed equipment.
Packaging · concept
Fig. 01
Isometric
Front elevationPouch forming and filling machine
A horizontal pouch machine concept that forms, fills and seals in one pass, with the filled pouches handed to a discharge conveyor. The layout puts the film path, the forming shoulder and the seal stations along one face so an operator can clear a fault without reaching across the machine, and the HMI sits at that same face. Modelled to fix the frame size, the film path and the discharge height before costing.
Form, fill and seal in one pass · Single-face operator access · Integrated discharge conveyor · Face-mounted HMI
Packaging · concept
Fig. 02
Robotic pouch filling cell
A concept that puts loading, forming, filling and sealing inside a single guarded enclosure, with a collaborative robot feeding pouches in at one end. Using a cobot for the load step keeps the infeed flexible across pouch sizes without a dedicated feeder for each format, and the enclosure was laid out so the robot envelope and the operator side never overlap.
Collaborative robot loading · Form, fill and seal enclosed · Multi-format infeed · Separated robot envelope
Food · concept
Fig. 03
Robotic tray palletiser
A fenced palletising cell that stacks product trays onto two pallet positions, so one pallet is being built while the other is changed out and the line never stops for a swap. The concept fixes the fence line, the gate positions and the reach envelope against the tray size and stack height the customer was already running.
Collaborative robot · Fenced cell · Two-pallet changeover · Continuous build
Packaging · concept
Fig. 04
Tube feeding and placing system
A feeding concept that takes tubes in bulk from a hopper, orients them through a step feeder and places them onto a conveyor with a servo arm. The step feeder does the orientation work mechanically, which keeps the placing arm doing one repeatable motion instead of correcting for however the tube arrived. Drawn to size the hopper, the feeder steps and the arm stroke against the target rate.
Bulk hopper infeed · Step feeder orientation · Servo placing arm · Rate-sized layout
Recent packaging engineering projects.
From CAD design to manufactured component. A selection of tooling projects delivered for thermoform packaging lines.
Concept to manufacture
Fig. 05
Design
ManufacturedCustom cutting blade inserts
From CAD design to manufactured tool. BioFlex designed a set of custom cutting blade inserts for a thermoform packaging line, modelled in 3D CAD with full design-for-manufacture review. The blade geometry was optimised for clean separation of formed packaging trays at line speed, with mounting features matched to the existing tool block to allow direct retrofit. The finished blades were CNC-machined from hardened tool steel to the dimensional tolerances and surface finish specified at design stage, ready for direct installation on the customer's line. From concept to finished tool in weeks.
3D CAD · Hardened tool steel · CNC machined · Direct retrofit · Concept to manufacture in weeks
Custom packaging design
Fig. 06
Custom thermoform packaging trays
Custom thermoform tray designs developed for retail product packaging, combining secure product retention, clear visibility for display, and efficient stacking for transport and storage. Each tray was designed around the specific geometry of the customer's product, with cavity placement optimised for material efficiency and forming consistency. Both designs were modelled in 3D CAD with design-for-manufacture review to ensure compatibility with standard thermoform line speeds and tooling constraints.
3D CAD · PET / PETG compatible · 4-cavity layout · Product-specific geometry · Retail-ready
Machine upgrade
Fig. 07
HEPA-filtered full-cycle packaging line
A full-cycle automated thermoform packaging line was upgraded with integrated HEPA filtration units along the forming, filling, and sealing zones, effectively converting the line into a semi-cleanroom production environment. The upgrade enables the customer to package products requiring elevated hygiene control without the cost of relocating the line into a dedicated cleanroom facility. The retrofit also included anti-static bars at the foil entry point and a top-foil UV station for surface treatment before sealing, improving overall product quality and reducing contamination risk.
HEPA filtration · Anti-static integration · UV sealing zone · Semi-cleanroom upgrade · Full-cycle retrofit
Engineering behind the line
BioFlex specialises in the mechanical engineering behind packaging production, from new mold and tooling design through to spare-part reverse engineering, machine modifications, and line integration. Our packaging work spans food, pharmaceutical, and industrial applications. We are not tied to a single material or format: if it runs on a packaging line and needs an engineering solution, we can scope it.
Services
- Thermoform mold design and manufacture
- Forming, sealing, and cutting tooling.
- Custom container and tray design
- Design-for-manufacture for thermoform constraints.
- Spare-part reverse engineering and supply
- Knife sets, mold inserts, conveyor parts, guards.
- Machine modifications and upgrades
- Format changes, output rate improvements, hygienic-zone upgrades.
- Automated filling line integration
- Robotic pick-and-place for solids, dosing systems for liquids.
- Safety guarding and interlocks
- Designed to EN ISO 13849 and machinery directive standards.
- Pharmaceutical and industrial packaging tooling
- Blister tooling, strip packaging, industrial tray systems.
- Full machine retrofits
- Re-cladding, ergonomic operator interfaces, hygienic-design enclosures.
Need a mold, spare part, or line modification?
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