IMA Coffee Hub highlights how it has developed new technology to enhance coffee capsule packaging processes and make products more sustainable.

In this golden age of innovation, developments in technology are helping coffee companies thrive in the fast-paced and evolving industry.

Through its constant analysis of the ever-changing coffee landscape, Italian coffee processing plant and packaging machine manufacturer IMA Coffee has recognised emerging trends in coffee capsule packaging. As part of its mission to provide solutions for its customers to meet current market demands, it has developed a new range of machines to cater for the packaging process.

“Nowadays, technologies for filling and sealing coffee capsules have to be as flexible as possible to adapt not only to different production rhythms but also to different capsule materials,” says Nicola Panzani, CEO of IMA Petroncini and Commercial Director of IMA Coffee Hub.

“New IMA Coffee machines have been created to boost the capsule filling and sealing potential of companies looking to reach higher targets.

“Our single-serve coffee capsule filling and sealing equipment can respond with high, medium, and low-speed capsule packaging solutions.”

According to Panzani, the demand for compostable packaging materials is on the rise. In response, IMA Group established the IMA OpenLab network of technological laboratories and testing areas dedicated to the research of sustainable materials, technologies, and production optimisation processes.

“Beyond the A to Z of coffee processing and packaging, IMA Coffee is committed to increasing sustainable practices to reduce roasting emissions and test alternative packaging materials, implementing advanced eco-friendly solutions throughout the industrial process to rise to the challenge of a more environmentally friendly industry,” he says.

“We see an increasing number of companies investing in sustainable packaging techniques to offset the environmental effect on the planet of traditional aluminium and plastic packaging. Demand for compostable coffee capsules is expected to grow as customers become more health conscious and aware of negative environmental repercussions of coffee capsule packaging.

“Compatibility testing on capsules, filter, and top lid films are performed at the IMA OpenLabs with the aim to identify and achieve optimum material sealing parameters and limits, as well as a suitable set up of IMA packaging machineries to handle compostable capsule materials successfully.”

The company believes its scientific approach has resulted in a unique solution for the market: its SYNKRO machine, specifically engineered for the capsule filling and sealing of compostable capsule material.

“Thanks to its innovative capsule transfer system based on the use of independent magnetic shuttles, SYNKRO guarantees high flexibility, allowing different dwell times at each operating station. This ensures even compostable materials requiring different sealing times can be optimally sealed without reducing the speed per cycle. It improves shelf life without compromising quality, and at comparable speed to standard materials,” says Panzani.

“Coffee capsules are complex structures where the capsule body, lidding, and filter must be precisely designed to deliver a consistently high-quality experience.

“Before the capsules reach the consumer, it’s important these components perform well during assembly, filling, and on the shelf. Coffee capsule preferences are always on the move, which is why IMA Coffee is prepared for any requests for packaging solutions.”

Aware of roasters’ concerns regarding the quality and freshness of coffee, Panzani highlights that the coffee capsule dosing, filling, and sealing units integrated in IMA’s machines maintain consistency from start to finish.

“We have created an innovative dosing unit that implements pre-compression to compact the coffee during capsule filling for a homogeneous product. This guarantees consistent dosing throughout each batch.”

When developing the machine, the team paid particular attention to reducing package material waste and focused on implementing a fully sustainable end-to end process.