Non-standard Customization Rectangle Sachet Condom Packing Machine

Custom Condom Packaging Solution: Long Sachets with High Lubricant Fill for Malaysian Client

Early last year, we received a custom request from a Malaysian company, Client P. They wanted a condom packaging machine that was anything but standard. Instead of the usual square or round sachets, they needed a long rectangular sachet format. On top of that, they required the machine to handle 1 to 2 times more lubricant or hyaluronic acid than typical products, along with several other specific features.

It sounded straightforward, but the real challenges were in the details: getting the long rectangular sachet to form correctly, managing the high-volume liquid fill without leaks, and ensuring the machine was practical for their local team to operate. After years in the packaging machinery business, we're used to clients with specific visions, so we got to work.

How We Tackled the Core Problem

The main hurdles were clear: high lubricant fill and the unusual sachet shape. Standard machines just wouldn't cut it.

We focused on structural modifications. To handle the extra lubricant, we adjusted the mechanical design to solve filling, containment, and leakage issues at the source. We also fine-tuned the forming and cutting modules so the round condoms would fit perfectly into the long rectangular pouches. The result was smooth production and a clean, consistent final product.

What Makes This Machine Special?

• Built for Local Use: We configured it for Malaysia's standard power (single-phase 220V, 50Hz). The single-lane design is a natural fit for the rectangular sachet packaging speed.

• User-Friendly: We added a manual loading plate, stacking plate, and single-lane conveyor. This makes the transition from manual feeding to automated packing simple for the operators.

• No More Leaks: A dedicated drip tray was installed to catch any excess lubricant during filling. This keeps the work area clean and prevents wasting expensive liquid.

• Stays Put: An adjustable limit stop on the frame prevents the machine from shifting during operation. We also simplified the cooling setup to just the air connections, as the client requested.

• Future-Ready: Thinking ahead, we预留 space, signal interfaces, and wiring for a well-known brand of inkjet printer. If the client wants to add coding or traceability later, they can do it without major machine overhauls.

• Spare Parts Kit: We included a set of common spare parts and consumables with the machine, so minor maintenance issues won't cause unexpected downtime.

Our Commitment to a Smooth Delivery

We set a 40-day lead time and followed a structured process from production through to testing. After commissioning, we provided the client with a full video of the machine running and high-resolution photos of every angle, plus samples of the finished sachets. Throughout the shipping process—from labeling and packaging to fumigation and loading—we documented everything and shared all the original photos with the client for full transparency.

The machine also comes with our own custom user manual, electrical diagrams, and a certificate of conformity, giving them a complete reference for operation and maintenance.

More Than Just One Machine

This project shows our capability in custom primary packaging. But we also have extensive experience with secondary packaging, like cartoning machines, for condoms. We can provide a fully integrated, customized packaging line if needed.

If you have specific requirements—like high lubricant fill, unique sachet shapes, or any other personalized packaging needs—feel free to get in touch. Whether it's a single machine or a complete line, we can tailor a solution that fits your actual production setup.