Laboratory inspection device for the analysis of cutting processes for packaging films




  • Not possible to check the cut edges when separating packaging materials
  • Lack of analysis method to evaluate the cutting quality
  • Lower cutting quality with monofilms (crimped edges, kinks and chip formation)

Research results

  • Methodical testing of the cutting behavior of films and film composites
  • Option to record measurable criteria (force, temperature, speed) for packaging material testing or testing of cutting quality of developed packaging material
  • Development of an inspection device for evaluating separation quality
  • Testing of the applicability under conditions close to series process


  • Reliable analysis option for the cutting process
  • Quality control during processing, production or on receipt of goods
  • Collection and evaluation of quality criteria for the production process
  • Improved product quality for the consumer

Material substitution support


When the multi-layer composites used to date are replaced by recyclable or more sustainable alternatives, such as monomaterials, their specific material properties place new demands on the manufacturing and processing procedures for packaging.

In order to be able to guarantee the required product properties and quality criteria with consistently stable, reliable and efficient processes, basic methods and test equipment are required to determine and analyze the process parameters.

As part of the HotCut project of the Central Innovation Programme for SMEs (ZIM), we are developing an inspection device that for the first time establishes a connection between the process steps of “sealing” and “cutting” and makes it possible to derive conclusions on optimum process parameters.


Determination of the optimum process window for monomaterials 


When separating joined packaging materials, the quality of the cut, which is highly visible at the POS (point of sale), has a significant impact on consumer acceptance. However, due to the specific material properties of monofilms in particular, visual defects often occur at the cut edges. These include pinch marks, kinks and chip formation.

The new inspection device makes relevant parameters of the cutting process of joined packaging materials visible and measurable. In addition to the values of force and speed, the film temperature in particular is a significant influencing variable in the separation process. The analysis of the collected data shows the correlations between the process parameters and enables the optimal process window to be determined.

The inspection device also creates the basis for a targeted material selection or the assessment of the material suitability of new packaging materials. What’s more, the HotCut enables standardized cutting tests and forms the basis for a methodical classification of the cutting quality and the development of a new test standard for the qualitative assessment of separation processes.


Task-oriented control panel


We have made use of the expertise of Fraunhofer IVV in the field of engineering psychology to develop the human-machine interface (HMI). As with the Pack Peel Scan, the design is based on the principle of task-oriented human-machine interaction. Taking into account the particularities of human perception, the information presented is adapted to the tasks of the operating personnel and the respective domain requirements. The HMI thus enables a better understanding of the situation and process, and makes it easier for operators to acquire knowledge.

If you have any questions or would like more information about our research project, please feel free to get in touch!


Additional project information


Project duration: July 1, 2022 to December 31, 2024
Cooperation partners: Andreas Siebler Verpackungsmaschinen,
HDG Verpackungsmaschinen GmbH
Project sponsor/Grant authority: Central Innovation Programme for Small and Medium-sized Enterprises (ZIM)