Detergent Manufacturing Equipment

Let’s discuss each step properly.







1. Film Feeding
In a linear detergent pod machine, it commences by feeding a roll of water-soluble PVA film into the production line. The film is rolled off in a smooth way so that straightening and tension can be done easily, and this process forms the base of the formation of pods in later stages.

2. Molding Station
When the film is in position, it travels to the molding area where heat and pressure are used to thermoform the film through the exact cavity shapes. Such pockets are expected to contain the detergent formula, l, and they are customized based on the size and shape of the pods.

3. Filling Station
The formed cavities are filled at a filling station where a measured quantity of liquid or gel detergents is filled. This allows delivery of each pod with an accurate dose, which keeps the product consistent, reduces wastage, and falls within the boundaries of quality control.

4. Sealing Station
This is then filled, and a second layer of PVA film is adhered on top of the filled cavities. This layer is then heat and pressure sealed to the base film to sandwich the detergent to form a leak-proof, tamper-proof pod.

5. Cutting and Output
The last process involves cutting the enclosed film with several pods into sizeable units. Such pods will then be automatically transferred to the output section, where they get collected, sorted, and transferred to packaging stations.



6. General Flow Process
In linear machines, all operations are placed with sequential steps according to straight-line movement, one after another, in the horizontal direction. These well-sorted-outakes outcomes make it easy to maintain and provide the option of expanding or adjusting the production line.



What is the working of Rotary Detergent Pod Making Machines?
So, here is the process for Rotary Detergent Pod Making Machines;



1. Film Placement
In the rotary detergent pod machines, the operation is initiated by laying the PVA film on a series of rotating dies around a central turret. The film will be fitted in place with a lot of accuracy so that it fits into every cavity of the die as the system rotates.



2. Rotary Molding
The rotating dies are then conveyed into a thermo-forming area, where the film is heated, nd under vacuum pressures is forced into pod shapes. In this rotary molding, the continuous motion is possible, and there is consistency in shell formation as well as high precision.

3. High-Speed Filling
Cavity packing is done by filling the formed cavities with the detergent solution through high-speed dispensing heads as the turret rotates. Several holes can be filled at once, which greatly raises the productivity of production without compromising precision.

4. Sealing and cutting
After filling, the pods are covered with a top layer of PVA film and sealed. The sealing station is coordinated with the turret and makes air-tight seals. The film is then chopped into pods, which are ready to be sent out.

5. General Process Flow
The whole rotary process works according to circular motion enabled by the turret. This layout optimizes production and minimizes machine footprint and opens up opportunities to work with high manufacturing throughput and minimum downtime.

Difference Between Linear and Rotary Machines
The following table gives a brief comparison between Linear and Rotary Machines;





Feature



Linear Machine



Rotary Machine





Production Layout



Straight-line setup



Circular/rotary setup





Speed



Moderate



High-speed





Footprint



Larger space requirement



Compact design





Maintenance



Easy to maintain



Slightly more complex





Flexibility



Easily customizable modules



Less modular





Production Volume



Ideal for small to mid-range volumes



Best for high-volume production





Initial Investment



Lower



Higher





Energy Consumption



Moderate



Optimized for large-scale use





Changeover Time



Shorter for multiple product types



Longer due to integrated design







Benefits of the Linear Detergent Pods Machines
So, here are some of its benefits;


Making Lower Initial Cost: Suitable for start-ups or small-scale manufacturers.
Flexible: Use of modular structure, which is expandable in the future.
Maintenance: It is easier to maintain and service the individual stations.
Quick Changeover: The speedier interchange of various pod sizes or formulas.
Scalability: The ability to insert new stations when the production expands.



Drawbacks of Linear Detergent Pod Machines
Let’s discuss the drawbacks.


Reduced speed of production: It is not applicable in large-scale production.
Space Requirement: A Linear layout will need more floor space.
Manual: Can require more frequent monitoring and tuning.
Increased Per-Unit Cost: uses a lot of resources to achieve higher volumes, which may affect profitability.

Benefits of Rotary Detergent Pod Machine
The following are the benefits of Rotary Detergent Pod Machine;


Massive Output: It is compatible with the mass production unit.
Compact Design: Maximizes floor space in the plant.
Standardization: Low variables and errors can be achieved through high automation.
Reduced manpower: Little or no manual work.
Scale Energy Efficient: Designed with uninterrupted, efficient manufacturing.



Drawbacks of Rotary Detergent Pod Machines
So, the rotary detergent pod offers the following challenges;


Increased Initial Investment: Needs a large amount of capital to begin.
Difficult Maintenance: It takes a more integrated system and thus skilled technicians.
Reduced Customization: It does not give much flexibility in quick production changes.
Less Time to Repair Problems: Smaller workspace implies that more structural components are involved during service.



When to Select a Linear Machine
One that suits startups or small-time manufacturing




Allows flexibility in switching of pod types and formula Linux servers 74
Cheaper price and less work to repair it.
It is best used in R&D or low production runs.
It is appropriate where space is not a limiting factor.

When to Use a Rotary Machine
The machines are used to manufacture high-level, high production velocities.




An excellent choice when it comes to bulk and commercial operations
Space-economical and automatically speedy and efficient
Scalable quality consistency
Makes the increased investment worthwhile with quick ROI

Applications
The two machines are used in the production of:


Detergent wash bags
Dishwasher pods
Unicon lavable capsules
Pro-industrial cleaning pods

Linear machines are typically applied in pilot-scale manufacture, R&D, or new market development, whereas rotary machines prevail in consumer mass manufacture.



Proper Guidance in Selecting the Right Machine
Although each of the two types of machines has its purpose of use, it is necessary to turn to industry experts when deciding what kind of machine to buy. Such factors as the pod size, film type, the liquid viscosity, the temperature during sealing, and the length of production shift examination influence.



The collaboration with a proven equipment provider can assist you both in considering all these parameters in their entirety and in aligning you with the most successful technology.



High-Speed Detergent Pod Option, the Polyva TD-350 Series
The high-speed category features one of the most spectacular choices POLYVA TD-350 Detergent Pods Making Machine. This series plays a part in ensuring a proper balance between speed, efficiency, and quality, whether you are upsizing or venturing into a competitive market.



It offers:


State-of-the-art gelatin pod technology
High-speed automatic packaging
Small and compact rotary design
High-quality seal and cutting accuracy
Easy user interface and real-time monitoring

Here are some of its specifications;







Specification



Explanation





Function



Automatic filling and sealing of pods





Suitable for



Laundry pods, Dishwasher pods





Packaging type



Double-layered bean pods





Film material



PVA / PVOH





Noise level



≤ 80 dB(A)





Machine weight



7 tons





Machine dimensions (L×W×H)



8200 × 3100 × 3700 mm









Why POLYVA is a Good Choice?
Industry Leader: The POLYVA focuses on the technology of water-solvable films and the machines of the product pod.


Custom Solutions: Machinery customized to your needs.
Services and training are available on a global basis.
Future-Proofing: Machinery that scales up as your company does.
Innovation that is on the Edge: Innovation in quality and automation.
Design and after-sales support: Contact POLYVA at any time and have a machine today and tomorrow that fits your needs.

Conclusion
The market of detergent pods is in full bloom, and it is possible to find the right production machine; it might all pay off. Regardless of the flexibility achieved by a linear machine or the efficiency brought about by a rotary system, you need to make your choice with your production objectives, budget, and your growth plan in mind.



In case you want high-volume, reliable output, you can use a solution that integrates performance and quality, such as the POLYVA TD-350. Ultimately, the correct decision will guarantee a stable quality of products, cost-effectiveness, and scalability, and will make your brand successful in a competitive market.



FAQs
1. Which works best with start-up detergent companies?

Start-ups are more accommodated by linear detergent pod machines as they are cheaper to set up and offer more options.



2. What is the speed of rotary machines in making pods?

Rotary machines such as the POLYVA TD-350 are capable of manufacturing thousands of pods per hour and, as such, are suitable to support high-demand operations.



3. Is it possible to alternate sizes of different pods in a single machine?

Yes. With linear machines, it is easier to switch between sizes and formats, and with rotary it may need downtime to switch.



4. What type of film is in these machines?

Both types of machines are compatible with PVA (polyvinyl alcohol) film, which is water resistant and environmentally friendly.



5. Is support provided after the purchase is done?

There are brands such as POLYVA that provide full cost post-sales services of training, repair, and troubleshooting.



6. What is the machine set time?

Installation differs according to models. Linear machines are normally quicker in terms of setting

As the global cleaning industry advances toward high efficiency, green manufacturing, and intelligent automation, POLYVA (Foshan Polyva Environmental Material Co., Ltd.) continues to lead the way. With over a decade of experience specializing in PVA water-soluble film and automated packaging technology, POLYVA introduces its latest innovation — the DS-160 fully automatic detergent pod packaging machine.

Compact, precise, and multifunctional, the DS-160 has quickly become the ideal choice for OEM and ODM manufacturers pursuing efficient production and consistent quality.






1. Compact Size, Powerful Performance — Small Footprint, High Productivity
The DS-160 adopts a compact vertical design (1300 × 880 × 1600 mm), requiring minimal installation space and offering flexible setup options.
Yet within this small frame lies tremendous capability — the system integrates automatic filling, forming, sealing, cutting, and discharging, achieving a truly one-click, start-to-finish production process.

Its modular structure makes maintenance and upgrades simple, while the transparent glass safety doors ensure full visual monitoring and operational safety. This combination of aesthetics and practicality allows operators to oversee production in real time with confidence.

2. Intelligent Guided Control — A System That “Understands” You
Traditional pod production lines are often complex and time-consuming to operate. The DS-160 changes that with its intuitive touchscreen interface, designed for simplicity and precision.
Operators can easily manage every process through a user-friendly guided system that supports:


One-click automatic operation
Dual-mold and dual-lane control
Real-time data monitoring and alarm notifications

This intelligent control system enhances production stability and minimizes manual intervention, ensuring a safer, smarter, and more efficient workflow.

3. Precision Engineering — Excellence in Every Detail
Every design detail of the DS-160 reflects POLYVA’s pursuit of manufacturing perfection:


Interchangeable filling heads for both liquid and gel formulations.
Independent servo-driven precision filling system with accuracy up to ±0.02 ml.
Single/dual-mold production modes to accommodate various capacity requirements.
Independent cutting system ensuring uniform pod size and easy downstream packaging.
Quick-change modular molds that reduce downtime and maximize continuous output.

Whether for mass production or R&D batch trials, the DS-160 adapts effortlessly. With a capacity of up to 6,000 pods per hour and 40% film material savings, it perfectly balances cost-efficiency with productivity.

4. Stability and Reliability — Engineered for Continuous Operation
Powered by POLYVA’s self-developed stable control system and optimized mechanical design, the DS-160 maintains smooth, quiet, and energy-efficient performance even at high speeds.

It integrates automatic alarm detection, temperature control monitoring, and precision positioning, allowing for extended operation without compromising accuracy.
For manufacturers demanding high standards and consistent quality, the DS-160 is a true production cornerstone.

5. Versatile Mold Design — Expanding Production Possibilities
Different markets and brands demand customized pod shapes and sizes. POLYVA understands this flexibility requirement and offers a variety of interchangeable molds for the DS-160, enabling quick transitions between square, oval, cyclone-shaped, and other custom designs.

The DS-160 is also compatible with multiple PVA water-soluble film thicknesses, making it suitable for diverse applications including laundry pods, dishwashing tablets, pesticide capsules, and disinfectant beads. One machine, multiple uses — maximizing investment returns.

6. The Technology Behind the Innovation — POLYVA’s Intelligent Manufacturing Strength
As a leading provider of PVA water-soluble films and water-soluble packaging solutions, Foshan Polyva Environmental Material Co., Ltd. delivers not just equipment, but complete end-to-end technical support — from raw materials to system integration and after-sales service.

With its core philosophy of “Eco-friendly · Innovative · Intelligent”, POLYVA continues to push technological boundaries, helping clients achieve efficient, low-carbon, and smart production in an increasingly competitive market.

The DS-160 embodies this philosophy — not just a machine, but a true engine of intelligent industrial transformation.

7. Conclusion: Small Machine, Big Future
In an era where smart manufacturing and green production are shaping the industry standard, POLYVA’s DS-160 stands out with its precision control, flexible configuration, and high operational stability.

It simplifies production, ensures consistent quality, and optimizes costs — turning every innovation into measurable results.
Looking ahead, POLYVA will continue to empower global clients with professional expertise and cutting-edge technology, offering smarter, more competitive solutions for the future of detergent pod manufacturing.

POLYVA — Smart Manufacturing for a Cleaner Future.

In the fast-paced cleaning product manufacturing industry, space, efficiency, and intelligence have become core competitive edges. The Polyva DS-160 Vertical Automatic Laundry Detergent Pod Packaging Machine, with its compact design and powerful performance, redefines the new standard for intelligent production.







Compact Size, Powerful Performance

With a machine dimension of only 1300×880×1600mm, it adopts a compact vertical structure design, featuring small floor space, neat wiring, and reasonable layout. Whether in laboratories, small-sized factories, or production workshops, it can be flexibly deployed and easily integrated into various production environments.

Fully Automatic Configuration, One-Click Start

Integrating Polyva's over a decade of experience in automatic packaging, the DS-160 is equipped with functions such as precise metering, automatic film forming, sealing, and cutting.No complicated operations are required—just a "one-click start" to quickly put it into production, realizing an efficient, stable, and sustainable production mode.

High Efficiency, Fast Response

The system has sensitive response, and the production process is automatically coordinated with seamless connection between all links.Whether for laundry pods, dishwashing pods, or other liquid single-dose packaging, the DS-160 can complete batch sampling and mass production with high speed and high precision.

Intelligent Control, Precise Mastery of Each Pod

Built-in intelligent control system, it monitors the operation status and parameter data in real time, ensuring each pod reaches the optimal state in links such as feeding, forming, and sealing.The user-friendly operation interface supports multi-language switching, making production more intuitive and efficient.

Green Intelligent Manufacturing, Energy-Saving and Efficient

Polyva Environmental Protection has always adhered to the concept of "green manufacturing".The DS-160 adopts an energy-saving design and a compatible solution for sustainable materials. While ensuring production capacity, it also helps enterprises save energy costs and facilitates environmentally friendly production.

DS-160: Making Efficiency More Compact, Making Intelligent Manufacturing Lighter

One machine, only one step switch from R&D to mass production.Choose Polyva to make intelligent detergent production more efficient, greener, and easier.

Foshan Polyva Environmental Protection Materials Co., Ltd.——Leader in Intelligent Detergent Equipment and PVA Water-Soluble Film Technology

In the competitive world of cleaning product manufacturing, speed and quality have become the twin pillars of brand success. As a company dedicated to the research, development, and production of detergent products, Foshan Polyva Products Co., Ltd. adheres to the core philosophy of “Smart Manufacturing Empowerment, Efficiency First.” Continuously introducing advanced automation technologies, Polyva has made the DS160 High-Speed Pod Packaging Machine a key driver of intelligent production and flexible manufacturing.





1. Ready-to-Run — Rapid Small-Batch Production
Facing the diverse demands of OEM and ODM clients, Polyva understands that speed means competitiveness.
The DS160 adopts a fully automated system — from liquid filling to sealing and forming, all processes are seamlessly integrated under intelligent control. With one-click startup, the machine quickly enters production mode, achieving true “plug-and-produce” capability.

Whether for trial production or small-scale custom orders, the DS160 enables brands to respond rapidly to market needs, shortening the cycle from R&D to product launch. For products like laundry pods or dishwashing tablets, this “fast small-batch production” capability provides a decisive market advantage.

2. Compact Design, Low Power Consumption
When it comes to space efficiency and energy management, the DS160 demonstrates remarkable performance.
With dimensions of only 1300 × 880 × 1600 mm, it occupies minimal floor space and fits easily into factories of various scales.

More impressively, its total power requirement is only 5 kW, and the machine’s independently controlled system enables up to 40% energy savings, significantly reducing operational costs.

For a high-efficiency manufacturer like Polyva, the DS160 represents more than just equipment—it’s a symbol of green productivity, perfectly combining low-carbon manufacturing with high production efficiency.

3. A Perfect Balance Between Speed and Precision
Equipped with intelligent servo drives and a high-precision filling system, the DS160 ensures uniform liquid dosing and stable pod forming. Even at high speeds, it maintains excellent sealing quality, minimizing defect rates.

The system offers customizable multi-cavity mold options, allowing seamless switching between 8g, 12g, and 20g pod sizes to meet different market demands. For Polyva, this flexibility means faster customization for clients—whether producing premium long-lasting fragrance pods or economical product lines, DS160 delivers precision and versatility.

4. Smart Production with Visualized Efficiency
The DS160 features an intelligent human-machine interface (HMI) with a user-friendly control panel.
Real-time data monitoring and adjustable parameters enable digitalized management throughout the entire production process.

This not only simplifies operation for production staff but also provides Polyva with reliable data support for quality control and process optimization.
With automatic alarms and safety protection systems, the DS160 ensures long-term stability, making production both efficient and secure.

5. Powering High-Quality Manufacturing for Global Brands
With years of expertise in the detergent industry, Polyva has always upheld the philosophy of “Equipment as the foundation, innovation as the soul.”
The introduction of the DS160 High-Speed Pod Packaging Machine enhances both productivity and the overall intelligence of Polyva’s manufacturing system.

From formula development to packaging, from sample testing to full-scale production, Polyva integrates advanced equipment with professional know-how to deliver comprehensive OEM and ODM services for clients worldwide.

6. Conclusion: In the Era of Smart Manufacturing, Efficiency Rules
In an age defined by high quality, short lead times, and product diversity, the DS160 High-Speed Pod Packaging Machine injects new momentum into detergent production.
It makes small-batch production more flexible, mass production more energy-efficient, and helps Polyva maintain a leading position in the industry.

Foshan Polyva Products Co., Ltd. will continue to uphold its spirit of professionalism and innovation, using technology to drive cleanliness and excellence. Every pod, every drop of detergent, embodies Polyva’s commitment to efficiency, precision, and quality.

— Polyva Smart Manufacturing: Making Cleaning More Efficient, and Brands More Exceptional.