As demand for gels across cosmetics, pharmaceuticals, personal care, and specialty food categories continues to rise, manufacturers must ensure accuracy, hygiene, and consistency at every stage of production. Thick, sticky, and highly viscous gels require specialized handling to prevent air pockets, maintain texture, and achieve precise dosing.
Our gel filling machine automates forming, dosing, and sealing within a single FFS (Form-Fill-Seal) platform. It increases throughput, reduces manual intervention, and ensures uniform product integrity for a wide range of gel-based applications.
Solution:
The gel filling machine uses controlled piston or servo-driven dosing to manage high-viscosity products without splashing, dripping, or underfilling.
Solution:
Automated forming, loading, and sealing eliminates repetitive manual steps, allowing your team to focus on production, not hand-filling.
Solution:
Degassing and precision dosing minimize trapped air, ensuring smooth, uniform fills that meet retail presentation standards.
Solution:
Supports cups, trays, tubes, sachets, and rigid containers, enabling smooth transitions between product lines without extensive retooling.
Face gels, hair styling gels, aloe gels, and moisturizing formulas.
Topical gels, OTC remedies, and medical-grade products requiring high hygiene and accuracy.
Edible gels, dessert gels, and high-viscosity sauces.
Ideal for emerging brands and small-batch gel production.
Up to 100 units/minute.
A flexible mid-range solution for scaling operations.
Up to 200 units/minute.
High-capacity industrial gel production.
Up to 300 units/minute.
Color Touchscreen
Allen Bradley components
Upper Film: Flexible film, paper, foil (up to 120 microns)
Pre-printed upper film
Lower Film: Rigid film, flexible film, foil (up to 1000 microns)
FFS 100:
2350 mm (W) × 1260 mm (D) × 2200 mm (H)
FFS 200:
2800 mm (W) × 1260 mm (D) × 2200 mm (H)
FFS 300:
2800 mm (W) × 1500 mm (D) × 2200 mm (H)
The gel filling machine forms, doses, and seals in one continuous workflow, stabilizing throughput and minimizing labor.
Push & Pull Conveying maintains container stability, allowing accurate, bubble-free fills even with dense or sticky gels.
Built specifically for gels that challenge standard filling equipment—ensuring clean fills and preserved product texture.
Compatible with rollstock sealing, lid sealing, and MAP for products that require extended shelf life.
Run 100–300 units per minute depending on the model, while maintaining consistent fill accuracy.
Works with tubes, pouches, trays, jars, and custom formats for retail, personal care, or pharmaceutical applications.
Designed for sticky or sugar-based gels, allowing quick disassembly, efficient cleaning, and minimized downtime.
As production demands grow, your FFS line must expand with you. Whether upgrading from manual processes or replacing outdated systems, this solution delivers stable dosing, hygiene compliance, and reliable performance for gel-based products.
The Hefestus gel filling machine ensures portion accuracy and clean dispensing across all viscosities, helping you maintain product quality while scaling output.
Request a demo or speak with our engineering team to evaluate your product, packaging format, and workflow requirements.
Yes, the dosing system is engineered for high-viscosity and sticky products.
Yes, optional hygienic configurations meet strict production standards.
Yes, pre-printed upper films are fully supported.
Yes, upgrades and tooling enhancements allow you to scale without replacing the full system.
Yes, controlled-temperature filling options protect delicate formulations.
Get expert guidance on scaling your automation line — from food to cannabis and everything in between.
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