Unit dose Form, Fill and Seal
Technology
Form Fill & Seal for unit dose
Unit dose packaging is a single-portion format widely used for liquids, syrups, vitamins, nutraceuticals, and cosmetic products. It provides convenience and ease of use for customers while ensuring accuracy, hygiene, and product protection. The production flow behind this format is based on the form, fill and seal principle. Two plastic film reels form a continuous band which is thermoformed inside the mould using compressed air. The cavities are then vertically filled by a volumetric pump, individually sealed in the heated sealing mould, and finally cut into strips according to the pre-set number of containers. This process guarantees a compact, hygienic, and cost-efficient solution, perfectly suited to a wide range of liquid products. With over 50 years of experience, IMA has become a reference in the field, offering solutions that combine high performance, hygiene, and adaptability to meet the evolving needs of modern production.
IMA’s unit dose systems are engineered for maximum efficiency and repeatable accuracy, ensuring each dose is consistently filled and perfectly sealed. User-friendly design principles allow for quick changeovers, easy cleaning, and flexible configuration, making them suitable for both large-scale industrial production and smaller batches.
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Key benefits
Consultancy step-by-step
Unit dose packaging often presents unique challenges that go beyond standard equipment. At IMA, consultancy means more than advising on machines—it is a collaborative co-design process. Our experts work directly with customers to develop the packaging itself, quickly assessing how the product, the chosen format, and the machine can work together seamlessly. This approach ensures that each solution is fully optimized from the outset, delivering both operational efficiency and packaging that meets functional, aesthetic, and regulatory requirements.
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Key benefits
Customization
Aesthetic appeal and product identity are increasingly important in cosmetic, food, and pharma sectors. IMA’s unit dose technology allows complete flexibility in packaging shape, size, and appearance, supporting marketing-driven design requirements. Whether producing compact single-dose sticks, flowing sachets, or bespoke formats, the machines can accommodate specialized geometries and finishes, delivering visually distinctive products that enhance consumer experience.
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Key benefits
Waste reduction
Efficiency and sustainability go hand in hand.
IMA’s solutions are developed in close cooperation with customers to minimize material waste. From careful design of the forming and sealing process to optimized handling of multi-dose strips, every step is engineered to reduce scrap without compromising product quality. The result is a tailored system that maximizes material use while maintaining high production efficiency. -
Key benefits
Materials division
Materials play a critical role in unit dose packaging, especially when working with multilayer films. IMA has a dedicated in-house material division with deep expertise in producing materials for unit doses, understanding how each film type behaves during forming, filling, cooling, and sealing. Leveraging this knowledge, we guide customers in selecting the optimal material and calibrating machine settings for consistent, high-quality output.
