Modular DoyPack Machines: Scalable Automation for Pre-Made Pouches
Compact doypack solutions: Flexible, scalable pouch filling, capacity from 50 to 2,000 pouches per hour.
Small-sized doypack automat for filling&sealing from vibratory tray, servo-piston pump, multy-head or auger doser.
LOCUS ROBOTICS’ modular DoyPack systems deliver cost-effective scalability for small-to-mid producers. Start with manual loading + basic filling; upgrade to full automation with sealing, coding, and case packing.
LOCUS ROBOTICS’ modular semi-automatic systems fill the gap between benchtop manual fillers and high-speed automatics. Perfect for producers scaling beyond 5,000 pouches/day who need:
✅ 45% smaller footprint than rotary systems
✅ 40% lower cost than full automatics
✅ <20-min changeovers with tool-free adjustments
Core Configurations
| Module | Function | Target Products |
|---|---|---|
| Pouch Denester | Auto-feeds pre-made pouches | All pouch types |
| Dosing Unit | Fill liquids/powders/solids | Sauces, granules, cosmetics |
| Gas Flushing | N₂/CO₂ injection (O₂ <0.5%) | Oxygen-sensitive foods |
| Sealing Station | Heat-seal zip-lock/spout pouches | Liquids, pastes |
| Coding/Labeling | Inkjet date coding + label application | Pharma, regulated goods |
Compact footprint vs rotary system comparison.
Modular Workflow
Pouch Loading: Manual or auto-denester
Pouch Opening: Pneumatic suction cups
Gas Flushing (Optional): N₂/CO₂ purge
Filling: Precision dosing (accuracy: ±0.5% liquids / ±0.2g solids)
Sealing: Dual-heat jaws (180–230°C)
Output: Conveyor to coding/labeling stations
Expansion Path
Start with:
Basic filler + sealer
Add later:
Precision Dosing Options
| Product Type | Recommended Doser | Accuracy |
|---|---|---|
| Granules/Nuts | Vibratory tray counter | Piece-count ±0.5% |
| Powders (cosmetics, spices) | Auger filler | ±0.2g |
| Liquids (sauces, oils) | Servo piston filler | ±0.5ml |
| Pastes (cosmetics, food) | Peristaltic pump | ±1% |
| Combos (dried fruits + liquids) | Hybrid multi-head | Custom |
Tool free doser changeover process.
Simplified Workflow
Operator loads: Stack of pre-made pouches + product in hopper
Automated handling: Suction cups open pouch → inert gas purge (optional)
Filling: Dosing nozzle descends + vibration plate settles product
Sealing: Copper jaws heat-seal zip-lock/spout
Output: Conveyor delivers finished pouches
Key Applications
Food: Nuts, dried fruits, candy, vitamin granules
Agriculture: Fertilizers, soil amendments
Cosmetics: Sheet masks, scrubs, powdered pigments, serums, hair dye in spouted pouches
Industrial: Granular additives, small-part packaging
Startups/Food SMEs: Sauces, coffee, spices
Chemicals: Detergents, automotive fluids
Pharma: Ointments, gels (ISO 13485 option)
Modular doypack system manual pouch loading.
Industry-Specific Packages
| Industry | Recommended Modules |
|---|---|
| Food | Auger filler + gas flushing + checkweigher |
| Cosmetics | Piston filler + excise labeler |
| Pharma | Peristaltic pump + CIP/SIP + 21 CFR Part 11 data log |
Technical Advantages
Throughput: 50–2,000 pouches/hour (scalable)
Changeovers: <15 mins with tool-free adjustments
Dosing Options: Peristaltic pumps (liquids), auger fillers (powders), vibratory trays (solids)
Compliance: CE, ISO 9001, GMP-ready (pharma models)
Technical Advantages vs. Automatics
| Feature | Modular Systems | Rotary Automatics |
|---|---|---|
| Footprint | 1.2m x 0.8m | 2.5m x 1.8m |
| Changeover | 10 mins (no tools) | 30-45 mins |
| Entry Cost | $25K-$45K | $75K-$150K |
| Daily Output | 5,000-6,000 pouches | 24,000+ pouches |
Suger filler module for spice pouches.
Compliance: CE, UKCA, EAC, ISO 9001 (GMP option)
Materials: 304 SS contact surfaces, FDA-grade seals
Power: 220V/50Hz or 110V/60Hz configurable
Pharma Compliance: Optional cleanroom compatibility (ISO Class 8)
Food Safety: All 316L SS contact surfaces, EHEDG-compliant seals
Upgrade Path: Add auto denesting → gas flushing → checkweighing
Target Users
Growing Brands: Beyond benchtop capacity (300+ pouches/hr)
Contract Packers: Frequent product/formula changes
R&D Facilities: Small-batch production with GMP traceability
Modular doypack machine filling nuts vibratory tray.
When you’ve outgrown benchtop fillers but aren’t ready for 200K+ pouches/month investments, our modular systems deliver:
2X output of manual machines.
1/3 cost of rotary automatics.
Pharma-grade precision with food/compliance packages.
VS Monoblocs: 35% lower entry cost; pay-as-you-grow scalability
VS Chinese OEMs: EU safety standards + local technical support
VS Linear Systems: Reconfigure layouts in hours (not days)
Upgraded line with excise labeler tobacco.
Free line configuration for your products, throughput validation testing!
Contact Packaging Engineers:
Compliance Roadmap:
CE, EAC, ISO 9001 certifications.
GMP-ready: 316L SS contact parts, CIP/SIP capabilities.
ATEX options for chemical solvents.
