POLYVA 160 Series Redefines High-Precision Water-Soluble Pod Manufacturing: DS160 & MP160

Industry Background: Evolution of Water-Soluble Pod Packaging and Market Demand for Specialized 160-Grade Machinery.
(POLYVA: https://www.polyva-pvafilm.com/)

Global Single-Dose Water-Soluble Packaging Market Expansion The global market for water-soluble single-dose encapsulated products has maintained a compound annual growth rate (CAGR) of 8.7% since 2020, driven by three pivotal industrial trends: global plastic reduction regulatory frameworks mandating biodegradable packaging adoption, end-user preference for pre-metered, portable single-dose chemical products, and supply chain optimization requirements for reduced logistics weight and storage footprint for concentrated liquid, gel, powder, and composite industrial formulations. PVA (Polyvinyl Alcohol) water-soluble film stands out among biodegradable packaging substrates for its complete aqueous dissolution, zero residual solid waste, customizable solubility temperature thresholds (cold-water, medium-temperature, high-temperature dissolution), high tensile strength, and excellent sealing adaptability to automated high-speed packaging lines, making it the dominant packaging material for household cleaning concentrates, industrial disinfectants, agricultural micro-fertilizers, water-soluble pest repellents, and specialty industrial chemical unit doses. Traditional early-generation water-soluble pod packaging machinery suffered from inherent structural defects limiting industrial scalability: outdated mechanical cam-driven filling leading to dosing tolerance exceeding ±0.5ml, manual film tension adjustment causing 35%-50% excess film consumption, fixed single-cavity mold structures requiring full machine disassembly for product specification switching, primitive relay-based control systems lacking real-time fault diagnosis, and structural framing unable to sustain continuous 24-hour operation with frequent mechanical fatigue and sealing failure. Small-scale startup manufacturers faced barriers of high upfront capital investment for large-format machines unsuitable for pilot batch testing, while multinational mass producers grappled with inconsistent pod dimensional uniformity, high reject rates during peak production, and limited cross-formula adaptability between low-viscosity liquids, high-viscosity gels, and free-flowing powder blends. This market gap created urgent demand for a dual-tier machinery platform: a compact, cost-effective vertical unit for small-batch R&D, pilot production, and medium-volume regional manufacturing, paired with a heavy-duty flatbed platform engineered for non-stop high-volume mass production, unified under a standardized 160 technical specification framework for component interchangeability, spare part commonality, and unified after-sales technical support-this is the core development objective of 's 160 Series product matrix. 1.2 's R&D Foundation for 160 Series Development 's 160 Series technical iteration is built on the enterprise's full industrial chain layout spanning PVA film formulation R&D, film casting production, packaging machinery mechanical design, servo control system programming, and production line turnkey integration. Since launching its first dedicated PVA pod packaging prototype in 2013, has accumulated proprietary intellectual property rights covering vacuum film forming, servo independent filling, low-temperature water-sealing technology, intelligent tension control for thin PVA film, and modular quick-change mold locking mechanisms, with over 42 utility patents and invention patents directly applied to DS160 and MP160 core subsystems. The company operates a 12,000-square-meter mechanical assembly workshop in Foshan, Guangdong, equipped with CNC precision machining centers, environmental simulation test chambers (high-humidity, temperature fluctuation, continuous load fatigue testing), and full-process offline production validation lines, ensuring every unit of DS160 and MP160 completes 72-hour continuous load testing, precision calibration, and compatibility verification with 's self-produced non-food-grade industrial PVA film series before factory delivery. Critical design premise confirmation for the 160 Series explicitly locked non-food-grade material standardization at the initial design phase: all wetted filling components, film contact mold surfaces, sealing rollers, and material transfer pipelines adopt industrial corrosion-resistant 304 stainless steel with industrial surface finishing (non-food-grade polishing standard), all matched PVA film substrates are formulated exclusively for industrial chemical encapsulation with additive systems unsuitable for food contact, and machine internal lubricants, sealant gaskets, and auxiliary process chemicals conform only to industrial safety specifications with zero compliance alignment to food hygiene regulations. This fixed design boundary eliminates any risk of cross-application to edible substance packaging and clarifies the equipment's exclusive positioning within industrial and household non-edible chemical manufacturing verticals.

DS160 Vertical Compact Packaging Machine: Small Footprint, High Precision for Pilot & Mid-Volume Flexible Production.2.1Overall Structural Design & Physical Specifications The DS160 is the vertical flagship compact model of the 160 Series, adopting a lean vertical integrated frame architecture with overall external dimensions of 1300mm (Length) × 880mm (Width) × 1600mm (Height), delivering ultra-compact floor occupation of merely 1.144 square meters, a defining competitive advantage for limited-space production environments including laboratory R&D workshops, startup pilot production rooms, small regional contract manufacturing facilities, and secondary production line expansion within existing factory layouts. The main frame is constructed with thickened carbon steel structural beams coated with industrial anti-corrosion epoxy paint, with all process contact functional modules (film unwinding station, vacuum forming station, servo filling unit, thermal water-sealing station, cutting assembly, finished product discharge conveyor) vertically layered in a streamlined top-to-bottom workflow to minimize material transfer distance, reduce PVA film stretch loss during conveying, and simplify daily cleaning access for residual formulation removal. Structural modularization is embedded throughout DS160's mechanical layout: independent detachable modules for film feeding, filling drive, sealing control, and post-processing sorting enable targeted component replacement without full machine shutdown, cutting routine maintenance downtime by 65% compared to integrated monolithic frame legacy machines. The unit supports single-operator standalone operation with plug-and-produce deployment requirements: standard factory power supply (380V three-phase industrial power), compressed air supply (0.6-0.8MPa stable air pressure), and circulating water supply for sealing temperature control are the only site prerequisites, with full equipment commissioning achievable within 4 hours post installation for qualified technical operators. Weight of the complete DS160 unit stands at 820kg, with built-in adjustable load-bearing casters and locking foot pads to facilitate workshop relocation and fixed-position stabilization during high-speed operation.2.2Core Performance Parameters & Production Capacity Metrics As a flexible dual-mode production platform, DS160 switches seamlessly between single-mold and dual-mold operational configurations to align output with client order volume requirements, with standardized peak production capacity reaching 6,000 pods per hour under dual-mold continuous operation, equivalent to 144,000 finished units within a 24-hour uninterrupted production window under stable operating conditions. Adjustable linear production speed ranges from 60 pods per minute (low-speed precision calibration mode for new formulation trial runs) to 480 pods per minute (high-speed standardized mass batch mode), with speed gradient adjustment configurable via the central touchscreen control panel without mechanical hardware modification. The quantitative filling system represents DS160's core technical breakthrough: an independent multi-channel servo-driven positive displacement pump filling architecture, with each filling pipeline equipped with standalone servo motor drive, flow sensor feedback, and real-time pressure stabilization modules, delivering industry-leading filling precision tolerance of ±0.02ml for liquid and gel formulations, and ±0.1g gravimetric tolerance for free-flowing powder encapsulation, eliminating inconsistent pod loading weight that causes product performance deviation and brand quality complaints. Standard filling volume coverage spans 8g to 25g per single pod cavity, with customizable cavity depth and mold sizing available for client-specific unit-dose capacity requirements, compatible with material viscosities ranging from 100mPa·s low-viscosity dilute concentrates to 2000mPa·s high-viscosity thick gel compounds without flow instability or incomplete cavity filling defects. A landmark economic advantage of DS160 is optimized PVA film material utilization efficiency, achieving up to 40% reduction in film consumption versus conventional vertical packaging machines via adaptive tension control, precision vacuum forming depth calibration, and narrow-edge sealing technology minimizing unused film border waste. For mid-volume manufacturers operating 8-hour daily shifts, this material saving translates to annual raw material cost reduction exceeding 32% for PVA film procurement, drastically shortening equipment return on investment (ROI) cycles, with typical client payback periods compressed to 6-9 months under stable full-capacity operation.2.3Intelligent Control System & Human-Machine Interaction Architecture DS160 integrates a PLC industrial main control unit paired with a 10-inch industrial capacitive touchscreen human-machine interface (HMI), supporting multi-language system switching (English, Spanish, French, Arabic, Russian, Mandarin Chinese) to accommodate global cross-regional operator teams, a critical feature for 's overseas client base spanning Southeast Asia, Europe, Latin America, and the Middle East. The control system encapsulates one-click automatic full-process startup, with pre-set production recipes storable for up to 99 distinct product specifications (different pod shapes, filling weights, film types, sealing temperature parameters); operators recall saved recipes with single touch to complete parameter synchronization within 3 seconds, eliminating manual repeated parameter input errors during product changeover. Real-time production data monitoring is embedded across every workflow node: film unwinding tension, vacuum forming negative pressure value, filling pump rotational speed, sealing roller temperature, cutting blade positioning, and finished pod counting data are visualized dynamically on the HMI, with automatic data logging to local storage and optional cloud data upload for enterprise production management system integration. A comprehensive intelligent fault diagnosis and early warning subsystem covers over 60 common operational anomalies including film breakage, insufficient air pressure, filling pump blockage, sealing temperature deviation, and overload current surge: the system triggers audible and visual alarms, locks hazardous operational actions, displays fault code troubleshooting guidance directly on-screen, and records fault timestamp and root cause for post-maintenance analysis, reducing unplanned downtime by 70% relative to legacy relay control systems lacking proactive protection. Safety interlock mechanisms comply with international industrial machinery safety standards: emergency stop buttons positioned at three accessible machine zones, safety light curtains at moving mechanical assembly access points, overload protection for servo drive motors, and pressure relief valves for pneumatic and hydraulic subsystems ensure operator physical safety during normal operation and emergency shutdown. All operational logs, production output statistics, and maintenance reminder alerts are archived automatically to support factory ISO quality management system audit compliance.2.4Formulation & Material Compatibility (Strict Non-Food-Grade Scope Only) Explicitly restricted to non-food-grade industrial materials, DS160 is validated for stable encapsulation of three major formulation categories exclusively for non-edible industrial and household chemical applications: 1. Low to high viscosity liquid concentrates: laundry cleaning concentrates, hard-surface cleaner liquids, industrial disinfectant solutions, agricultural foliar nutrient liquids, water-soluble biocide formulations 2. Thixotropic gel and paste compounds: thickened stain remover gels, descaling paste concentrates, industrial lubricant gel single doses 3. Free-flowing micro-powders and granular blends: water-soluble agricultural fertilizer micro-granules, deodorant powder blends, industrial descaling powder unit doses Compatible packaging substrates are limited to 's proprietary non-food-grade industrial PVA film portfolio (L0200, L0800, L0900 cold/medium/high-temperature soluble series), custom-calibrated for DS160's vacuum forming and low-temperature water-sealing process to preserve complete film solubility post-sealing without thermal degradation of water-soluble functional properties. All film variants paired with DS160 are certified industrial-grade with formulation additives optimized for chemical resistance to alkaline, acidic, and surfactant-rich cleaning formulations, with zero certification for food contact safety, and cannot be deployed for any edible substance containment under any operational scenario. Quick-change modular mold systems support customizable pod geometry including spherical, rectangular, heart-shaped, multi-cavity dual-chamber structures, enabling clients to launch differentiated branded single-dose products without purchasing additional standalone machinery; mold replacement is completed within 15 minutes by a single trained operator, further boosting production flexibility for small-batch customized order fulfillment.2.5Target Application Scenarios for DS160 1. R&D laboratories and formulation innovation departments of chemical brands: small-batch trial production of new cleaning, agrochemical, and disinfectant formulations for stability testing, market sample production, and regulatory compliance pre-verification 2. Startup manufacturing enterprises and regional small-scale contract manufacturers: entry-level automated production replacing manual semi-automatic packaging lines, low initial capital investment with scalable output growth 3. Mid-sized household chemical manufacturers: auxiliary flexible production line for limited-edition product runs, seasonal peak demand supplementary capacity, and multi-SKU mixed batch production 4. Educational and industrial technical training institutions: machinery operation training for packaging technology majors, technical skill certification practice for industrial automation operators

3.MP160 Flatbed High-Speed Mass Production Machine: Heavy-Duty Continuous Operation for Large-Scale Global Brand Manufacturing.Flatbed Integrated Structural Advantages & Mechanical Durability The MP160 serves as the high-volume production counterpart within the 160 Series, engineered with a full flatbed horizontal frame structure optimized for uninterrupted round-the-clock mass production, designed to resolve the structural limitations of vertical machines in sustained high-speed continuous operation including mechanical vibration amplification, film conveying instability under long runtime, and uneven heat distribution across sealing surfaces during extended shifts. The flatbed layout horizontally arranges film unwinding, preheating, vacuum forming, multi-station filling, double-sided sealing, continuous cutting, and automatic sorting along a linear production track, with reinforced heavy-duty cast iron base frame eliminating operational vibration even at maximum speed, maintaining dimensional consistency of finished pods across weeks of non-stop production. While MP160 features a larger overall footprint than DS160, it retains space-saving integrated component layout with centralized utility piping and wiring harness management, suitable for dedicated large-scale production workshops with standardized assembly line planning. Core load-bearing rotating components (main drive spindle, sealing roller bearings, cutting actuator shafts) adopt imported high-precision wear-resistant alloy steel with surface hardening treatment, delivering a designed service life of 80,000 continuous operational hours without major component replacement, drastically reducing long-term lifecycle maintenance costs for mass producers operating 24/7 production schedules. All material contact surfaces maintain the same non-food-grade industrial stainless steel specification as DS160, with industrial anti-corrosion coating resistant to alkaline and acidic residual formulation corrosion, compliant only with industrial chemical hygiene standards, not food-grade sanitization requirements. MP160's vacuum forming subsystem upgrades DS160's single-chamber vacuum structure to a segmented multi-stage vacuum adsorption system, with independent negative pressure regulation for each mold cavity row, ensuring uniform film stretching and forming depth consistency across the entire mold plate even at maximum line speed, eliminating edge pod under-forming or central pod over-stretching defects common in entry-level flatbed machines. Integrated film preheating rollers with segmented temperature zoning adjust surface heat distribution based on PVA film thickness and solubility grade, preventing localized film melting or brittleness during high-speed forming.Peak Production Capacity & Precision Filling Optimization for Mass Output MP160 achieves a maximum linear production speed of 520 pods per minute, translating to 31,200 pods per hour stable continuous output, with synchronized multi-row mold plate design enabling simultaneous forming and filling of up to 8 parallel pod cavities per production cycle, tailored for multinational FMCG brands, large agrochemical manufacturers, and global OEM contract packaging factories with million-unit daily order requirements. Despite extreme high-speed operation, the servo collective filling system retains ultra-high dosing precision: grouped servo pump banks with individual feedback correction loops maintain ±0.03ml liquid filling tolerance and ±0.12g powder gravimetric tolerance at full speed, a critical performance metric to ensure uniform product efficacy across millions of mass-produced pods for global branded product quality standardization. Compatible filling volume range mirrors DS160's 8g-25g single cavity capacity, with support for multi-chamber composite filling (2-cavity, 3-cavity, 4-cavity integrated pods) for blended multi-functional formulations, allowing simultaneous encapsulation of chemically compatible separate concentrates in a single pod unit for premium differentiated product lines. Material viscosity adaptability is extended to 2500mPa·s ultra-high-viscosity gel formulations via upgraded high-torque servo filling pumps with anti-clogging self-cleaning pipelines, suitable for concentrated industrial descaling gels and heavy-duty cleaning paste encapsulation. Film material efficiency on MP160 reaches 96% raw material utilization rate, exceeding DS160's excellent benchmark through continuous closed-loop tension control, edge trimming waste recovery guidance, and adaptive sealing width reduction technology; large-scale manufacturers utilizing MP160 for annual production volumes exceeding 50 million pods achieve six-figure annual savings on non-food-grade PVA film procurement costs, strengthening gross profit margins for mass-produced commodity single-dose products.Industrial-Grade Intelligent Control & Centralized Production Line Integration Capability MP160 is equipped with an industrial-grade modular PLC control system compatible with factory MES (Manufacturing Execution System), SCADA centralized monitoring platforms, and automated upstream formulation feeding lines and downstream cartoning packaging lines, enabling full unmanned integrated production line construction for smart factories. The 12-inch industrial touchscreen HMI supports hierarchical access permission management (administrator, supervisor, operator, maintenance technician) with role-locked parameter modification authority, preventing unauthorized operational adjustments in large factory team environments. Continuous production stability control algorithms are customized for long-hour operation: the system dynamically adjusts motor operating temperature, sealing roller thermal compensation, and film tension baseline in real time to counteract mechanical thermal expansion and environmental humidity fluctuation during 24-hour runtime, maintaining consistent product quality from startup to 72-hour non-stop shutdown without manual mid-shift calibration. Advanced predictive maintenance sensors monitor vibration frequency, bearing temperature, and servo motor load rate for key components, generating proactive component replacement reminders before mechanical failure occurs, eliminating unplanned production halts during peak order fulfillment periods. Automatic post-processing subsystems integrated standard on MP160 include high-speed counting, defective pod automatic rejection (via weight and shape optical inspection), finished product conveyor stacking, and batch coding synchronization with downstream secondary packaging machinery, forming a seamless end-to-end production workflow from raw formulation feeding to final carton sealing without intermediate manual handling.
Primary Deployment Scenarios for MP160 1. Multinational fast-moving consumer goods (FMCG) leading brands: global regional mass production of standardized single-dose cleaning product lines for cross-border market distribution 2. Large-scale agrochemical enterprises: bulk packaging of water-soluble granular fertilizers, liquid crop protection agents for agricultural bulk supply chains 3. Third-party global OEM/ODM contract packaging factories: multi-brand high-volume turnkey packaging service for multiple client SKUs with rapid recipe switching 4. Industrial disinfectant and public hygiene product manufacturers: continuous production of bulk single-dose disinfectant pods for commercial facility sanitation, municipal hygiene procurement.

One-Stop Turnkey Solution for 160 Series Global Clients: Beyond Equipment Supply to Full Lifecycle Support.Customized Non-Food-Grade PVA Film Matching Service Every DS160 and MP160 purchaser gains access to 's in-house PVA film formulation customization team, which develops tailored non-food-grade industrial PVA film grades matched to client-specific formulation chemistry (high-alkali cleaning liquids, acidic disinfectants, high-salt agrochemical solutions) and regional climate conditions (high-humidity tropical markets, low-temperature temperate zones). Custom film tuning optimizes solubility timing, sealing compatibility, and storage stability of finished pods, eliminating incompatibility risks between third-party generic film and 160 Series machinery. All customized film output remains strictly non-food-grade with formal material certification disclaimers confirming exclusion from food contact applications. Global Installation, Commissioning & Technical Training deploys certified field service engineers to client production sites worldwide for equipment installation, mechanical calibration, power and utility connection, and initial production trial run validation, with full equipment acceptance testing signed off before formal handover. Standard training packages include 3-tier technical certification: basic operator training (HMI operation, recipe recall, routine cleaning), intermediate maintenance training (component replacement, fault code troubleshooting), advanced technical certification (parameter deep calibration, minor mechanical adjustment). 7×24 Global After-Sales Lifecycle Maintenance A global after-sales network covering Southeast Asia, Europe, North America, Latin America, Middle East, and Africa provides 7×24 remote technical support via video call, with regional spare part warehouses stocking critical 160 Series interchangeable components for expedited delivery (3-7 days global standard delivery). Extended warranty packages (2-year standard warranty, optional 5-year premium industrial warranty) cover core servo motors, PLC controllers, filling pumps, and sealing assemblies, with on-site emergency repair dispatch for critical production downtime events for large-scale MP160 mass production clients. Long-term equipment upgrade pathways allow DS160 users to retrofit high-speed modules to expand capacity gradually as business scales, protecting initial capital investment value.OEM & ODM Co-Development for Differentiated Product Innovation For brand clients and contract manufacturers, offers deep ODM collaborative development combining 160 Series hardware customization, mold shape exclusive design, formulation encapsulation process optimization, and packaging structural innovation (multi-chamber pods, shaped decorative pods, dual-color sealed pods). The R&D team co-develops production process parameters to realize exclusive branded product differentiation, with full intellectual property protection for client custom mold designs and proprietary production recipes, supporting clients to capture premium market positioning in the competitive single-dose packaging sector, all within non-food-grade product application limits.

Environmental Compliance & Sustainable Manufacturing Value of 160 Series Beyond production efficiency and precision, 160 Series aligns with global circular economy and carbon reduction policies via three core sustainable design pillars: 1. Biodegradable Packaging Enablement: Optimized compatibility with fully biodegradable PVA water-soluble film eliminates persistent plastic waste from single-dose packaging, meeting EU Single-Use Plastics Directive, North American plastic reduction regulations, and global corporate ESG sustainability reporting requirements for FMCG and agrochemical enterprises. 2. Energy-Efficient Mechanical Design: High-efficiency servo drive systems replace traditional constant-speed asynchronous motors, reducing unit product power consumption by 28% compared to legacy packaging machinery; intelligent standby power management cuts idle energy use during production gaps, lowering factory carbon footprint for continuous MP160 large-scale operation. 3. Minimal Raw Material Waste: Precision dosing and adaptive film tension control minimize formulation overflow and PVA film scrap generation, reducing industrial waste discharge and lowering client waste disposal costs, while residual non-hazardous industrial formulation waste is compatible with standard industrial chemical recovery protocols compliant with environmental protection regulations.

onclusion: 160 Series Positions as Global Leader in Tiered Water-Soluble Pod Manufacturing Technology The 160 Series, integrating the compact flexible DS160 vertical unit and heavy-duty continuous MP160 flatbed platform, constructs a complete tiered machinery solution matrix covering the full lifecycle of encapsulated product development: laboratory R&D trial → small-batch pilot production → medium-volume regional manufacturing → large-scale global mass production. Built on 12 years of proprietary PVA material science and packaging machinery R&D, the dual-model lineup resolves longstanding industry pain points of precision inconsistency, material waste, operational inflexibility, and continuous runtime instability, while rigid adherence to non-food-grade material specifications clarifies safe, compliant industrial application boundaries for all global end-users. For emerging manufacturers, DS160 delivers low-risk entry into automated water-soluble pod production with scalable growth potential; for established multinational industrial and household chemical brands, MP160 unlocks cost-efficient, stable high-volume mass production for global market rollout, with unified after-sales, film customization, and technical collaboration services creating closed-loop competitive advantages unavailable from fragmented third-party machinery suppliers. As global demand for eco-friendly single-dose industrial packaging continues upward trajectory, 's 160 Series will remain the benchmark technical reference for precision, sustainability, and operational versatility in non-food-grade water-soluble pod encapsulation technology worldwide.

POLYVA was founded in 2014. Our founding team has a thorough understanding of polyvinyl alcohol materials and their industrial application and has rich practical experience in product research and development of water-soluble film and enterprise operation.

POLYVA's three business scopes: high-speed automatic water soluble film packaging machine, OEM and ODM services of water soluble film and water soluble film packaging application products. We have more than 500 employees, and the business sectors complement each other. The business scope includes raw material research and development, application equipment research and development, packaging consumables, and demonstration factories, and has become a leading brand in China's water-soluble packaging industry.

POLYVA
77-3 Datang A Zone, Central Technology Industrial Zone of Sanshui District, Foshan, China
+86 17796067993
web@polyva.cn
Tony

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