Tetra Pak® A3/Flex

Versatility of shapes, sizes and closures

  • Easy conversion between different family package shapes and sizes
  • Easy adaptation to many different closures
  • High food safety (unique aseptic process FDA filed)


Automatic material supply

Uninterrupted production

There's no need to halt production in order to refill with packaging material or strips since both are replaced automatically. Automation also ensures that splices between packaging material reels and strip applications are of consistent, repeatable quality.

Aseptic zone

Ensures aseptic conditions in an economical way

The flow of sterile air needed to maintain aseptic conditions is fully controlled in a closed loop, and designed to auto-correct if deviations occur. The smallness of the aseptic zone leads to savings in the consumption of both power and peroxide.

Deep peroxide bath

For safer packaging material sterilisation

A peroxide bath, as opposed to a spray system, sterilises the packaging material inside and out. A special thermal carpet keeps the peroxide bath at the optimum sterilisation temperature.

Servo driven jaw system

Adding flexibility and reducing waste

Using servo-motors, the jaw system profile is created in a software model rather than mechanically. This facilitates rapid conversion between different kinds of package production. Profiles are optimised to give better looking packages; printed package designs are synchronised to reduce waste.

Operator interface

Enabling operators to work swiftly and efficiently

Several factors contribute to the easy operation of this filling machine: the Tetra Pak Operator Panel with its intuitive touch screen interface; large windows through which operators can observe production at first hand, and ground level access to essential working parts.

PLMS centre

Operational control and performance analysis

The PLMS centre automatically collects production data from the automation platform. To this, the operator can add his own observations. Improvements in production efficiency can then be made on the basis of the two.

iLine automation platform

More reliable production

As the filling machine is an integrated part of the line it communicates with all the other line equipment. Sterilisation, filling and sealing processes are continuously controlled, increasing the output of 'on-target' packages. This feature also enables selectable capacity for compatibility with existing processing or downstream equipment.

Improved final folder design

Turning out better looking packages, faster

Packages are released from the machine in an upright position, which simplifies the production process and increases reliability. Servo-motors accelerate the final folding process to give a good package shape and high capacity. They also enable the production flexibility offered by QuickChange and Volume Conversion functions.


Headspace by Injection

Headspace is necessary for products that need to be shaken before consumption. It also makes it easier to open and pour from the package.

The unit consists of a control cabinet, a heating element to sterilize air (or an inert gas) and a nozzle which injects the sterile air (or inert gas) to the product to create froth. When the froth settles down, it leaves a residual headspace which enables the content to be shaken and mixed. Using this method, products can be filled by weight so the choice of volumes is wider

DIMC on Pre-Laminate Hole (PLH)

Direct Injection Moulding Concept for a low-cost, highly functional opening

The flat packaging material with a PLH is fed into the DIMC unit and therein the neck of the screw-cap opening is injected over the PLH using the direct injection moulding technology.
The actual lid is screwed on to the neck downstream by the Capper.
The DIMC unit is placed at floor level for easy operator access.

Integrated PullTab Unit

Integrated between the ASU and the main body of the filling machine, this unit enables production of packages with a PullTab opening.

The PullTab Unit punches a hole in the packaging material then applies an Inner PE-Strip and an outer Aluminium Tab (which is later used for opening the package). The opening is hermetically sealed before the packaging material proceeds to forming and filling.


QuickChange technology makes it possible to switch production between two packages with the same bottom cross section, whilst maintaining the filling machine’s sterile conditions.

The module consists of six parts that need to be changed by the filling machine operator. After this has been done, the machine automatically adjusts by applying the servo motor programme for the new volume chosen. Within 15 minutes, the machine can be ready to start production again.

DIMC QuickChange™

Allows switching from Tetra Brik® Aseptic 1000 Edge LightCap™ 30 to Tetra Brik® Aseptic 500 Edge LightCap™ 30 in a quick and simple way

For the first time we can offer a DIMC QuickChange™ on Tetra Pak® A3/Flex which allows switching from Tetra Brik® Aseptic 1000 Edge LightCap™ 30 to Tetra Brik® Aseptic 500 Edge LightCap™ 30 in a quick and simple way. Using the Volume Conversion Kit QuickChange™ it is possible to change production between two packages with the same bottom cross section in only 15 minutes.

Do you want more information about Tetra Pak A3/Flex? Please contact us.