Horizontal flow packaging · Twinline
Twinline Model
Servo horizontal flow wrapper for biscuits, cookies and cakes in two stacks per pack.
Twin-lane infeed, film unwind and AISI 304 stainless product-contact parts.
Up to 900
products per minute
2 x 1 to 2 x 4
customizable pile pack ratios
75 mm / 30 mm
max. biscuit diameter / height
18 kW
installed power, 400 V/50 Hz, 460 V/60 Hz, 220 V/60 Hz
Overview
About the Twinline
The Twinline is the stacked-product model of the Protrus Horizontal Flow Pack Packaging range. It is built for high- efficiency packaging of biscuits up to 75 mm in diameter and 30 mm in height: biscuits arrive in two lanes, are counted into two short stacks and are pushed into the film side by side, so one pack holds 2 × 1, 2 × 2, 2 × 3 or 2 × 4 pieces. With servo motors and a fully automated system the machine handles up to 900 products per minute. The pack is a classic pillow with a fin seal underneath and crimped end seals, tight around the pile so the biscuits cannot slide and break in transport. Pile ratio, pack length, pitch and seal settings are stored as recipes on the 10 in Omron touch screen, which turns a change from a four-piece to an eight-piece pack into a recipe call and a short guide adjustment.
From oven output to a tight pile pack
A pile pack (also called a stack pack or slug pack) groups several flat, round products into one flow pack. It is the standard format for portion and on-the-go packs of biscuits because the stacks protect each other and the pack uses little film. On the Twinline the product path stays on a horizontal line: the distribution system splits the oven output into lanes, the pile former builds two stacks of the set count, a lug chain carries each pair into a film tube, bottom discs close the tube with a fin seal and rotary jaws seal and cut between the piles. Nothing stops between packs, which is how the machine keeps up with a biscuit oven.
Why choose Twinline
Built for stacks Twin-lane counting forms two piles per pack without hand loading; 2 × 1, 2 × 2, 2 × 3 and 2 × 4 ratios are set per recipe.
Hot and cold seal Heated sealing for biscuits and cakes; pressure-only sealing for coated products.
Line-scale feeding One modular distribution line can feed multiple wrappers; a stock band buffers short stops.
Servo precision Omron servo motors and motion control, digitally controlled cutting length and print-mark registration.
Hygienic access Drives behind the frame; removable food-grade belts and AISI 304 product- contact surfaces.
Products & pack styles
Photorealistic product and packaging concepts for the Twinline range.
Typical products are cakes, biscuits, double biscuits, biscuit piles, pile packs (2 × 2, 2 × 3 and 2 × 4) and choco pie, in flat, stackable formats up to 75 mm in diameter and 30 mm in height. Typical room conditions: 18 to 20 °C to keep coatings firm and limit moisture pickup. Protrus matches film, jaws, guides and infeed to your product.
Double biscuits | 2 x 3
Butter biscuits | 2 x 4
Coated biscuits | 2 x 2
Chip cookies | 2 x 3
Oat cookies | 2 x 3
Round crackers | 2 x 4
Cocoa biscuit pile pack
Wafer rounds | 2 x 1
Pile configurations and output
| Pile | Pieces per pack | Output, pcs/min* | Typical use |
|---|---|---|---|
| 2 × 1 | 2 | Up to 250 | Large biscuits, cakes and choco pie as twin packs |
| 2 × 2 | 4 | Up to 220 | Double and coated biscuits, school and snack packs |
| 2 × 3 | 6 | Up to 170 | Double biscuits and cookies, single-serve portions |
| 2 × 4 | 8 | Up to 120 | Butter biscuits and biscuit piles, family snack packs |
* Capacity per pile configuration from the Twinline technical data. Overview rating: 80 to 120 pcs/min on cold-seal and on hot-seal film, up to 900 products per minute. Product, pile height, film and configuration determine final output; confirm by trial.
Film and seal guide
| Product group | Recommended film | Seal | Handling note |
|---|---|---|---|
| Butter, tea and double biscuits | OPP or BOPP | Hot seal | Tight pile pack keeps edges from chipping |
| Chocolate-coated biscuits and choco pie | OPP or BOPP | Cold seal | No heat on the coating; room at 18 to 20 °C (typical) |
| Cookies | OPP, CPP or BOPP | Hot seal | Soft-contact guides for crumbly products |
Packaging films: OPP, CPP and BOPP. Product and packaging images are AI-generated representative concepts, not production samples.
Built around your line
Modular biscuit distribution from oven or cooling conveyor to one or more wrappers.
Biscuits leave the oven or cooling conveyor in wide rows. The automatic distribution system takes over at a set infeed height (typically about 1,000 mm), aligns the rows, divides them into lanes and sends each lane to its wrapper; synchronization belts set the pitch and a stock band holds a short buffer, so a film change on one wrapper does not stop the oven. The system is modular: belts are food grade on AISI 304 plates that lift out without tools, each unit has scrapers and a drip tray, self-lubricating bearings run at the tight belt turns, and pneumatic belt tracking stops the conveyor if air pressure is too low to steer. At the wrapper, servo vacuum belts set each pile into the lug chain; an air-blast ejector removes broken or misplaced pieces at full speed, and an optional turning unit rotates products by 90°.
Twin-wrapper system fed from one oven line
Branched distribution for multiple wrappers
Lane guides
Row alignment station
Roller chutes between levels
Twinline in an L-shaped layout with automatic biscuit feeding.
Film handling, layout and options
Film unwind. Single reel holder for rolls up to 350 mm in diameter and 300 mm wide on a 70 to 76 mm core; mechanical film centering and guide rollers keep the web flat and in line.
Layouts. Straight, L-shaped or twin-wrapper systems are drawn to the factory plan; machine dimensions are project-specific.
Options. Inkjet or thermal coder (date coder input included), metal detector, checkweigher, 90° turning and a case-packing interface.
Specifications
Technical specifications
Standard reference data. Final values depend on product, pile and film and are confirmed in each Protrus offer.
| Parameter | Twinline Model | Note |
|---|---|---|
| Machine type | Servo horizontal flow wrapper (HFFS) with twin-lane pile infeed, fin seal underneath | Pillow pack, two stacks per pack |
| Capacity | 2 × 1: 250 · 2 × 2: 220 · 2 × 3: 170 · 2 × 4: 120 pcs/min | Up to 900 products/min |
| Overview rating | Cold seal 80 to 120 pcs/min; hot seal 80 to 120 pcs/min | Configuration-dependent |
| Product size | Biscuits up to 75 mm (3 in) diameter and 30 mm (1.2 in) height | Other sizes on request |
| Film reel | Double reel holder; max. roll diameter 350 mm (13.8 in), roll width 600 mm, core 70 to 76 mm | |
| Film handling | Mechanical film centering; digitally controlled cutting length | |
| Packaging films | OPP, CPP and BOPP materials | Samples tested by Protrus engineers |
| Sealing | Hot and cold sealing | Cold seal for coated products |
| Fin seal discs | 3 disc sets: puller, single heater and folding | |
| End-seal jaws | Rotary jaw set with straight or zigzag blades | Jaws open automatically at standstill |
| Registration | Digitally controlled cutting length, print-mark registration with automatic correction | |
| Chain conveyor | Pile-specific pusher fingers and side guides; mechanical chain tensioning | Double-product detection stops the machine |
| Pile infeed | Twin-lane counting and pile forming, servo vacuum belts, air-blast reject, optional 90° turning unit | Modular, can be extended later |
| Control | Omron PLC, motion control, servo drives and inverters; Omron servo motors; 10 in Omron HMI | Recipe per product |
| Components | Siemens and Schneider electrical equipment, DKP control cabinet, ELK AC motors, Tramec (Italy) gearboxes, Omron relay modules, Sick photoelectric sensors, safety limit switches and emergency relays, SMC pneumatics, SKF/FAG/ORS bearings | |
| Electrical supply | 400 V/50 Hz, 460 V/60 Hz, 220 V/60 Hz; 18 kW installed | Depends on configuration |
| Compressed air | 6 bar (87 psi) | Dry, oil-free air |
| Weight | Approx. 3,500 kg (7,700 lbs) | Flow pack machine |
| Dimensions | Project-specific, drawn to suit the customer’s factory layout | |
| Construction | Surfaces in contact with the product AISI 304 stainless steel | Date coder input included |
Frequently asked questions
Get a Quote
Plan your biscuit pile pack line with Protrus
We test your product, propose the distribution layout and prepare a budget offer for the Twinline Model Horizontal Flow Wrapper.
Prefer email? info@protrus.com