THE SDP 501Z Delta, commissioned by Kamboo, the local agent for XL Plastics Machinery, was installed to address waste, inconsistency and downtime. Operations manager Mike Schlachter describes its impact: ‘The machine is smooth, stable and predictable. When I saw it during qualification in India last September and commissioning here in January, the contrast with our previous machines was clear.’

The machine was affectionately nicknamed PJS, after his daughter, Poppy Jane. ‘We haven’t had PJS long enough to explore everything it’s capable of, but its performance has been consistently reliable,’ Mike says.

He adds that this predictability has changed the rhythm of production. ‘Since commissioning PJS, Kangopak has reduced waste by 20-30%.’ Speeds now reach 150 cycles per minute, depending on format and substrate. The cut-off unit and packing table increase speed without adding workload for the packers due to cleaner changeovers and fewer interventions.

‘The difference is in the stability. There’s less manual adjustment, less film plucking and fewer sealing issues. Our operators monitor rather than constantly correct,’ Mike explains.

For converters producing stand-up pouches, three-side seal formats and zipper variants – across both laminated and mono-material structures – that level of stability is fundamental.

Kangopak also focuses on unprinted pouches where tension control is critical and inconsistencies show immediately without print to mask them. PJS reduces tension issues, making production less operator-dependent – a significant point of difference for the company.

Servo precision

Control is a central feature. According to Ketan Rathod, XL Plastics’ exports manager, the SDP’s electronic line shaft servo-driven sealing system enables precise adjustment of dwell time, delivering accurate and consistent seal integrity. ‘By replacing mechanically timed systems with fully synchronised, programmable control, it enhances precision and repeatability,’ he notes. The bi-directional retracting sealing jaws further reduce heat exposure and mechanical stress on the film when not engaged, supporting improved material handling and extended component life.

‘With servo systems, you’re controlling the process rather than reacting to it,’ Ketan adds. ‘Seal integrity remains consistent because pressure and timing can be fine-tuned electronically. Once initial parameters are set, the machine automatically adjusts to maintain sealing quality even at higher operating speeds.’

Higher speeds are only useful if quality holds. The industry’s transition to recyclable mono-material structures, including mono-PE and MDO-PE, introduces new variables. These substrates behave differently from conventional laminates, with narrower heat windows and increased tension sensitivity.

‘Mono-material structures are leaner and more sustainable, but they’re far less forgiving,’ explains Ketan. ‘Any fluctuation in tension or inconsistency in sealing control quickly results in defects. The SDP is engineered to manage that material variability, giving converters the confidence to transition to sustainable substrates without sacrificing throughput.’

The difference is in the stability. There’s less manual adjustment, less film plucking and fewer sealing issues. Our operators monitor rather than constantly correct.”

From setup to performance

Kamboo’s involvement extended beyond delivery and installation. ‘You’re not just buying equipment, you’re buying support. Having local technical backing, plus access to the OEM, gives you confidence to push the machine,’ Mike says.

Russell Muller, national sales manager at Kamboo, adds: ‘Anyone can sell a machine on a brochure. The real test is how it performs in a live production environment under pressure, running different substrates and managing real-world changeovers. Our role continues after installation. We work with Kangopak to make sure the machine is optimised, operators are confident and output targets are achieved.’

Ketan believes that the South African packaging market is demanding greater durability and consistency. ‘That’s exactly where we see opportunity,’ he asserts. ‘As demand grows for stronger, more reliable packaging, we’re well positioned to support converters with robust, performance-driven solutions.’

The investment also reflects a broader shift in the South African flexible packaging landscape. Pouches continue to gain ground across food, health and specialty segments, driven by logistics efficiency, shelf presence and portion flexibility. Retailer-led sustainability targets are also accelerating the move to recyclable materials.

‘Pouches aren’t secondary anymore, but expectations around quality, sustainability and speed are higher. You have to tighten your process, and that’s what this machine offers us,’ Mike says. ‘We’ve grown year-on-year. This machine strengthens that path. Higher output, lower waste and better consistency. Reliability is what matters.’

XL Plastics: a legacy in bag and pouch making

XL Plastics has built a strong global presence in bag and pouch making technology. Established in 1980 by founder Dhirendra Vora, the company has grown from a domestic manufacturer into an internationally recognised supplier with more than 5 000 installations across 35 countries. Now led by second-generation directors Vivek and Rahul Vora, the business continues to expand its footprint while staying rooted in strong engineering fundamentals and practical machine design.

XL Plastics offers a comprehensive portfolio of bag and pouch making machinery serving sectors such as bakery, hygiene, FMCG, stationery, vacuum packaging, shrink sleeves and specialised pet food packaging applications.