Drive solutions for sports gel production

Whether it's professional or recreational sports, whether in a national league or local division, whenever athletes push their limits to achieve their goals, nutrition and nutrient supply play a vital role. Dextrose, isotonic drinks and sports or energy gels help athletes perform at their best and stay in top form during intense exertion. Sports gels, in particular, have recently gained popularity due to their compact form, making them easily accessible during training and competition. But how do these sports gels end up in their handy packaging? The answer is simple, precise and reliable: with the state-of-the-art machines from Scaldopack and the linear motors from FAULHABER.

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High performance through cutting-edge technology

There are many different sizes, varieties and flavors of these sports gels, often with varying compositions to meet specific needs. The production process requires meticulous care, from the recipe to packaging. Before the sports gel finds its way into an athlete's bag, it must be properly filled into its packaging. Scaldopack, a company based in Belgium, develops and manufactures machines that automatically fill and seal these gels into pouches. The machines are customized to meet specific requirements, including the selection of pouches, spouts and closures. The demands are high: low total operating costs must be maintained, fast production changeovers must be possible, minimal maintenance is required, and energy efficiency, waste reduction and 24/7 availability must be implemented to optimum effect.

Linear drives for maximum efficiency

For the smooth and efficient operation of these machines, Scaldopack relies on FAULHABER's BLDC motors – direct linear drives with built-in Hall sensors. These provide positioning accuracy of up to 1/10 mm with an acceleration of up to 4G. The compact unit, with dimensions of 22 x 22 x 74 mm, achieves a peak force of 27 N and offers exceptional long-term reliability: it can operate continuously for nearly three years without maintenance – an enormous advantage compared to conventional pneumatic components.

In addition to reliability, the ease of integration and operation of the machines are decisive factors. The FAULHABER MC 3603 ET Motion Controller significantly simplifies both integration and the necessary testing. The EtherCAT-CiA402 functionality, with integrated reference cycle, positioning and touch probe functions, allows for the seamless implementation of this dynamic controller. For perfectly matched drive systems and machines that deliver peak performance.