Enabling compostable teabags through sustainable machine modernization
Project snapshot
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Challenge
Modernizing obsolete machinery to support sustainability
The customer’s existing teabag machines, installed in the 1950s/60s, had become obsolete and could not support future production or factory growth. They needed a solution that would prolong the life of the machines, improve production efficiency, enable the use of new compostable PLA teabag tissue, and safeguard UK jobs while supporting sustainability commitments.
Innovation
New sealing technology and servo-controlled automation
We designed a solution that modernized the machinery and enabled sustainable teabag production:
- Developed a new sealing drum assembly with precise heater control to process PLA teabag tissue
- Implemented servo-controlled axes to replace cam-and-chain technology, reducing vibration
- Achieved circa 40% throughput increase over legacy machines
- Enabled faster machine start-up with reduced material waste
- Reduction in plastic usage with more sustainable cartoning
Result
Sustainability and efficiency gains
The customer now uses fully compostable teabag materials, has extended machine life, and increased production efficiency by approximately 30%. The sealing technology was patented, and the upgrade has strengthened the long-term partnership between AIR and the customer.
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