DPP90Communion Cup
Filling & Sealing Machine
From PVC thermoforming and liquid filling to biscuit placement, secondary lidding, and final die-cutting—all on a single continuous production platform.
One platform.
A complete communion cup.
The DPP90 combines cup thermoforming, liquid filling, first-layer sealing, manual biscuit placement, secondary lidding, and cutting in one inline machine.
PVC roll stock is formed into cups. The liquid is filled and sealed with Aluminum + PE film before the biscuit is placed above the first seal. A second layer of transparent printed film completes the combo packaging.
Main application: Communion Cup + Biscuit combo packaging.
From roll stock to finished product.
The liquid is sealed first. The biscuit is then placed above the aluminum foil seal before secondary lidding.
- 01PVC Feeding
- 02Heating
- 03Thermoforming
- 04Liquid Filling
- 05Aluminum Foil Sealing
- 06Biscuit Placement
- 07Transparent Printed Film
- 08Secondary Sealing
- 09Die-Cutting
- 10Finished Product
Key Engineering Highlights of the DPP90
Integrated Multi-Stage Packaging Process
The entire process—from PVC thermoforming, liquid filling, and initial sealing to biscuit placement, secondary lidding, and final die-cutting—is completed on a single continuous production platform.
Cam-Driven Mechanical Transmission
Cam-driven mechanical transmission synchronizes key mechanical movements; the clear structural logic makes the system ideal for continuous cyclic production and long-term operation.
Anti-Drip Plunger Filling
Small-dose plunger filling (1–30 ml range) featuring an anti-drip design to minimize post-filling liquid leakage.
40–80 Cups/min
Standard 100 mm version:
40 cups/min
Widened 200 mm version:
80 cups/min
Dual-Side Biscuit Loading Area
A spacious open area is provided for manual biscuit placement following the initial aluminum foil sealing step.
Two operators can work simultaneously from both sides.
Double-Layer Heated SUS304 Hopper
A double-layered SUS304 heated hopper paired with SUS304 liquid piping ensures optimal transport and temperature maintenance for liquid food products.
Approx. 30-Minute Mold Changeover
Switching between different communion cup specifications is achieved through a quick mold changeover process.
Compact 2.5 m Inline Platform
Multiple production steps are integrated within a machine length of approximately 2.5 meters, minimizing the overall footprint of the production system.
Explore the Machine.
See the Details.
From the complete machine to the filling, loading and sealing areas.
Small-dose filling.
Controlled delivery.
Small-dose plunger filling (1–30 ml range) featuring an anti-drip design to minimize post-filling liquid leakage.
A double-layered SUS304 heated hopper paired with SUS304 liquid piping ensures optimal transport and temperature maintenance for liquid food products.
Space to work.
Access from both sides.
A spacious open area is provided for manual biscuit placement following the initial aluminum foil sealing step.
Two operators can work simultaneously from both sides.
Aluminum Foil Sealing → Biscuit Placement → Transparent Printed Film → Secondary Sealing
Two film widths. The same cycle speed.
Select either the 100 mm or 200 mm configuration based on the target output.
100 mm Film Width
200 mm Film Width
Final parameters are subject to adjustment based on cup type, film width, filling liquid, sealing materials, printed film, and mold configuration.
Key Technical Parameters
| Parameter | DPP90 |
|---|---|
| Equipment Model | DPP90 |
| Equipment Type | Automatic thermoforming, filling, and sealing machine |
| Main Application | Communion Cup + Biscuit combo packaging |
| Cycle Speed | 20 cycles/min |
| Standard Film Width | 100 mm |
| Standard Cups per Cycle | 2 cups |
| Standard Output | 40 cups/min |
| Wide-Version Film Width | 200 mm |
| Wide-Version Cups per Cycle | 4 cups |
| Wide-Version Output | 80 cups/min |
| Standard Communion Cup Capacity | Approx. 5 ml |
| Filling Range | 1–30 ml |
| Filling Accuracy | ±0.5 ml |
| Filling Method | Piston-type anti-drip filling |
| Liquid-Contact Materials | SUS304 |
| Hopper | Double-layer heated SUS304 hopper |
| Piping | SUS304 |
| Standard Cup Diameter | 37.5 mm |
| Standard Cup Height | 24 mm |
| Max. Forming Depth | 24 mm |
| Forming Width | Designed for film widths up to 200 mm |
| Bottom Film Material | PVC |
| First Sealing Layer Material | Aluminum + PE |
| Second Packaging Layer Material | Transparent printed plastic film |
| Main Drive Method | Mechanical cam drive |
| Mold Changeover Time | Approx. 30 min |
| Air Pressure | 0.8 MPa |
| Air Consumption | Approx. 200 L/min |
| Cooling Water | Not required |
| Standard Power Supply | 380V / 3 Phase / 50Hz |
| Voltage Customization | Customizable to local voltage standards |
| Total Power | Approx. 3 kW |
| Machine Dimensions | Approx. 2500 × 800 × 1600 mm |
| Machine Weight | Approx. 800 kg |
| Lead Time | Approx. 45 days |
Final parameters are subject to adjustment based on cup type, film width, filling liquid, sealing materials, printed film, and mold configuration.
What must the customer provide before placing an order?
To confirm the final configuration of the DPP90, customers are advised to provide:
1. Communion Cup samples or dimension drawings
Including:
– cup diameter
– cup height
– flange
– target volume
2. Actual filling liquid
Providing actual samples is preferred. AFPAK can verify the following based on the actual liquid:
– Flowability
– Filling performance
– Anti-drip performance
– Whether hopper heating is required
3. PVC base film
Specifications to confirm:
– Material
– Thickness
– Width
4. Aluminum + PE sealing material
Specifications to confirm:
– Material structure
– Thickness
– Heat-sealing parameters
5. Second-layer transparent printed film
If the brand design is finalized, actual printed film can be provided for testing.
6. Target output
Examples:
– 40 cups/min
– 80 cups/min
Select either the 100 mm or 200 mm configuration based on the target output.
Sample Testing and Project Confirmation
Before formal production, it is recommended that the customer send actual packaging materials and liquid samples to AFPAK.
This ensures the best possible alignment of the product, materials, and machine configuration before shipment.
Based on the samples, we complete the following:
- Cup shape confirmation
- Mold design
- Filling test
- First-layer sealing test
- Biscuit placement confirmation
- Second-layer transparent film confirmation
- Punching/cutting layout confirmation
- Continuous operation test
Pre-shipment Quality Inspection
Before the DPP90 leaves the factory, inspection should go beyond simply verifying that the machine starts up.
Key tests recommended:
- Stability of PVC feeding
- Consistency of forming dimensions
- Integrity of cup shape
- Accuracy of filling volume against settings
- Absence of significant nozzle dripping
- Stability of first-layer aluminum foil seal
- Suitability of biscuit placement space
- Correct positioning of second-layer transparent film
- Proper functioning of secondary sealing
- Accuracy of punching/cutting position
- Synchronization during continuous operation
Actual Production Video
See how the DPP90 produces a complete Communion Cup unit.
FAQ
How many Communion Cups can the DPP90 produce per minute?
The standard 100mm version produces 2 cups per cycle at a speed of 20 cycles/min, resulting in a standard output of approximately 40 cups/min.
The 200mm widened version produces 4 cups per cycle; running at the same 20 cycles/min, it achieves a maximum output of approximately 80 cups/min.
Is the Communion Cup limited to a 5 ml capacity?
No.
5 ml is the typical capacity for a Communion Cup.
The DPP90’s filling system supports an adjustable range of approximately 1–30 ml.
What are the standard cup dimensions?
Current standard Communion Cup:
– Diameter: approx. 37.5 mm
– Height: approx. 24 mm
Other cup types can be evaluated via custom molds.
Can it package both liquid and a biscuit simultaneously?
Yes.
The liquid is sealed first (Aluminum + PE), then the unit moves to the manual biscuit placement area, followed by the application of a second layer of transparent printed film for the outer packaging.
Is biscuit placement done by one person or two?
The machine provides ample workspace in the manual biscuit placement area.
Two operators can stand on opposite sides of the machine to place biscuits simultaneously.
How long does it take to change Communion Cup specifications?
The standard mold change time is approximately 30 minutes.
After the mold change, checks for positioning, temperature, filling volume, and sealing quality are required.
Is cooling water required?
The current DPP90 configuration does not require an external cooling water supply.
How much compressed air does the machine require?
Operating air pressure: approx.
0.8 MPa
Air consumption: approx.
200 L/min
Can it be manufactured to match local voltage requirements?
Yes. Standard configuration:
380V / 3-phase / 50Hz
Customization based on local voltage standards is also available.
Do I need to send samples before placing an order?
It is highly recommended.
Especially for:
– PVC
– Aluminum + PE foil
– Transparent printed film
– Communion liquid
– Biscuit / wafer
Testing with your actual materials is more reliable than configuring the machine based solely on dimensional drawings.
Send us your communion cups, liquid, and packaging materials.
AFPAK can then confirm the DPP90 configuration based on your actual products.
Please provide:
- Communion cup dimensions / samples
- Target fill volume
- Actual liquid
- PVC roll stock
- Aluminum + PE sealing film
- Transparent printed film
- Biscuit / wafer
- Target output
Based on this information, we will confirm:
- 100 mm or 200 mm
- Cups per cycle
- Mold specifications
- Filling parameters
- Sealing materials
- Punching/cutting layout
- Final production plan
