| Sumario: | This study presents a novel approach to enhancing traveler health and food safety by optimizing sachet-filling machine parameters for single-serve instant beverage packaging. Three main variables were investigated under controlled experiments: metallized film thickness (55, 75, and 95 μm), sealing temperature (125, 135, and 145 °C), and filling speed (slow, medium, and fast). Packaging performance was evaluated through three mechanical indicators package distortion, adhesion to the cutter, and seal integrity which are directly linked to hygienic and safety outcomes. Excessive distortion can compromise package stability and facilitate contamination, poor adhesion may lead to surface irregularities that harbor impurities, and weak seals increase the risk of microbial ingress and moisture penetration. Results indicated that increasing film thickness from 55 to 95 μm reduced cutter adhesion but caused higher distortion. Higher sealing temperatures (145 °C) improved adhesion, but combined with higher filling speeds, seal integrity deteriorated. Optimal conditions were identified at 75 μm film thickness, 135 °C sealing temperature, and medium filling speed. These settings minimized distortion and adhesion while ensuring strong sealing performance. The findings highlight how mechanical packaging characteristics act as proxies for safety assurance, offering a practical basis for industrial processes that reduce contamination risks and support consistent, hygienic single-serve packaging for travelers.
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