Hydroforma technology for single-dose pods
Mespack designs and manufactures Hydroforma machines that form, fill and seal water-soluble pods in PVOH film, for liquids, powders or both, with 1 to 5 chambers. Two series cover every stage of growth: the Hydroforma Rotary Series, with up to 2,400 pods per minute, and the Hydroforma Flat Bed Series, the latest evolution in hydroforming technology.
Water-soluble pods are single-dose packs made from PVOH film that dissolves in water, releasing a precise dose of product. Hydroforma machines produce pods with 1 to 5 chambers, combining liquids, powders or both in the same pod, with cavities customised for each brand. Multi-chamber pods keep formulations separate until use and create a distinctive product on shelf. A 5-chamber format is also available, for maximum separation of ingredients in a single dose.
A single liquid or powder dose in one compartment.
A liquid and a powder combined in one pod.
Two liquid formulations kept separate until use.
Three liquids in one pod for multi-action products.
Round multi-chamber pod for premium formulations.
Laundry and dishwasher detergents, fabric softeners and cleaning concentrates. Servo-driven filling delivers an accurate dose in every pod, and Dual Shot filling doubles liquid output on the Hydroforma 660 DS.
Dishwasher and laundry powders, water treatment products, agrochemicals and protein powders. Dedicated powder dosing systems with dust control, and pouch deflation options to keep powder pods dry for secondary packaging.
Liquid and powder loaded simultaneously in separate chambers of the same pod. Hybrid pods combine ingredients that cannot be mixed and deliver a complete treatment in a single dose.
From laundry detergents to agrochemicals, pods deliver a precise dose with no direct contact with the product.
Laundry and dishwasher detergents, fabric softeners, floor cleaners, disinfectants and toilet bowl cleaners.
Pre-measured doses of pool and water treatment chemicals, with no handling of concentrated product.
Crop protection and fertiliser doses that reduce operator exposure, dust and vapour inhalation.
Industrial cleaning products, concrete additives and other chemicals in safe, accurate unit doses.
Selected applications such as hair bleach pods and protein pods, including edible films.
Water-soluble pods turn concentrated products into safe, convenient and precisely dosed single units.
Every pod contains exactly the right amount, avoiding overdosing and product waste.
Users never touch the product, with less dust and minimised vapour inhalation.
Drop the pod in and the film dissolves completely: no measuring, no spills, no mess.
Concentrated, compact doses reduce product volume, packaging and transport costs.
Separate chambers combine incompatible ingredients and create a distinctive product.
PVOH film dissolves in use, supporting eco-friendly packaging and less material per dose.
Cavity detection: if the film is not formed correctly, no product is filled, avoiding waste and clean-ups.
Servo-driven precision filling and patented gentle handling that protects pods during and after cutting.
Scalable range from the Hydroforma 165 to the 660 DS, with up to 2,400 pods per minute.
Prototype trials on a Cloud Hydroforma machine and laboratory to test formulation, film and pod.
Support from development and validation to industrial production, and changeovers in under 90 minutes.
Closed dosing with dust aspiration on the machine, and no product contact for the end user.
Lower cost per pod through less waste, accurate dosing and Athena production data analytics.
The success of a pod product depends not only on its formulation, but on pod consistency, efficiency, waste and the ability to scale. Mespack combines proven technology with engineering, product development and global service.
Mespack acquired Cloud Packaging, inventor of the original rotary-drum pod technology, trusted by pod manufacturers worldwide.
From a first pod product or new brand to established high-volume operations, with machines sized to each goal.
From product development and validation to industrial production, with Hello Mespack remote support available 24/7.
Presence in over 90 countries and production facilities in Spain, the United States and India.
Mespack acquired Cloud Packaging, inventor of the original rotary-drum pod technology.
The Mespack Hydroforma FB Series is our last innovation in water-soluble pod packaging machine, it has reduced machine footprint and high production of up to 2000 ppm.
More information
Mespack's Hydroforma Series includes fast changeover time, low machine footprint, and speeds up to 2400 ppm.
More information
Mespack offers complete pod lines: Hydroforma machines produce the pods, Mespack HFFS machines pack them into stand-up pouches, and secondary and end-of-line systems complete the line. Hydroforma machines are designed to reduce film waste and product losses, and the PVOH film dissolves completely in use.
Mespack offers complete pod lines: Hydroforma machines produce the pods, Mespack HFFS machines pack them into stand-up pouches, and secondary and end-of-line systems complete the line. Hydroforma machines are designed to reduce film waste and product losses, and the PVOH film dissolves completely in use.
A water-soluble pod is a single-dose pack made from PVOH (polyvinyl alcohol) film that dissolves completely in water, releasing a precise dose of product. Pods are widely used for laundry and dishwasher detergents, and also for water treatment, agrochemicals and industrial chemicals. They can hold liquids, powders or both, in one or several chambers.
Mespack, a Duravant company, designs and manufactures water-soluble pod packaging machines under the Hydroforma brand. Mespack acquired Cloud Packaging, inventor of the original rotary-forming drum technology, and offers two series: the Hydroforma Rotary Series for very high-speed production and the Hydroforma Flat Bed Series, the latest evolution in hydroforming technology.
The Hydroforma Rotary Series forms pods on a rotary drum and reaches up to 2,400 pods per minute in powder and 1,400 in liquid, with compact models for smaller budgets. The Hydroforma Flat Bed Series forms pods on a flat bed, combining horizontal form fill seal know-how with water-soluble film technology, and reaches up to 2,000 pods per minute in liquid, pasty or powder products. Mespack recommends the right series after assessing product, pod design and output.
Output depends on the machine, pod size, product and film. The Hydroforma 660 and 660 DS reach up to 2,400 pods per minute in powder, and the 660 DS reaches up to 1,400 pods per minute in liquid thanks to its Dual Shot filling system. The Hydroforma 330 reaches up to 1,200 pods per minute in powder and 450 in liquid, the Hydroforma 165 up to 600 in powder and 180 in liquid, and the Hydroforma 660 FB up to 2,000 pods per minute. Final speed is confirmed after product and film testing.
Hydroforma machines produce pods with 1 to 5 chambers, depending on the model. Multi-chamber pods keep different formulations separate until use, combining liquid and liquid or liquid and powder in the same pod. This allows brands to include incompatible ingredients in one dose and to create visually differentiated products.
Hydroforma Rotary machines produce pods up to 152.4 x 152.4 mm, with a depth of up to 18 mm and a volume of up to 50 cc. The Hydroforma 660 FB produces pods up to 90 x 90 mm and 18 mm deep. Cavities are customised for each customer, so the pod shape and volume are defined during project development.
Pods are made from PVOH (polyvinyl alcohol) water-soluble film, available in different grades, with or without bittering agents. Typical thicknesses are around 50 microns for powder pods and at least 76 microns for liquid pods. Chemical compatibility between film and product is validated with the film supplier. The Hydroforma Flat Bed can also work with edible films.
Yes. Mespack offers prototype trials on a Cloud Hydroforma machine so manufacturers can test their formulation, film and pod design during product development. Trials help validate dosing, sealing, pod integrity and expected output before industrial production, reducing scale-up risk and time-to-market.
The right thermoforming machine depends on the product formulation, number of pod chambers, required output, film characteristics, dosing complexity, available floor space, and future capacity requirements. Manufacturers should also consider format changeover needs, automation level, maintenance accessibility, and integration with downstream equipment. Evaluating these factors together helps select a Hydroforma configuration aligned with both current production targets and long-term operational objectives.
OEE in water-soluble pod production is mainly influenced by machine availability, production speed, dosing consistency, sealing quality, film handling, format changeover time, and the frequency of rejects or unplanned stops. Stable process parameters and effective preventive maintenance are also essential. Monitoring these variables helps manufacturers identify losses, improve operational efficiency, and maintain consistent industrial performance across different products and formats.
A Hydroforma machine can form part of a complete line that includes product preparation, dosing, pod inspection, transfer systems, secondary packaging, case packing, palletizing, and end-of-line automation. Successful integration requires coordinated product flow, compatible line speeds, suitable accumulation capacity, and centralized control. This approach can reduce manual handling, improve traceability, and create a more consistent production process from pod manufacturing to finished pallet.
Yes. Scalability can be considered through the initial machine configuration, available dosing capacity, automation level, downstream equipment, and space reserved for future line expansion. Manufacturers should evaluate not only their current output but also expected format diversification and production growth. A scalable approach helps avoid premature equipment replacement and supports future investment in additional automation, secondary packaging, or higher-capacity end-of-line systems.
Material savings depend on controlling film tension, forming conditions, dosing accuracy, sealing parameters, and product transfer. Incorrect settings can generate malformed cavities, product losses, weak seals, or unnecessary film consumption. Consistent process control and early detection of deviations help reduce rejects. Manufacturers should also evaluate pod dimensions and dosing tolerances to ensure that the package uses only the material and product required for its intended function.
A suitable maintenance strategy combines preventive maintenance, condition monitoring, planned inspection of critical components, and analysis of recurring machine stops. Particular attention should be paid to forming, dosing, sealing, cutting, and film-handling systems because their condition directly affects pod quality and machine availability. Structured maintenance planning can reduce unplanned downtime, improve spare-parts management, and support more stable production performance.
Water-soluble films and hygroscopic products can be sensitive to environmental and process conditions. Humidity, temperature, product viscosity, powder flowability, and chemical compatibility should therefore be evaluated during package development and machine configuration. Controlling these variables helps support reliable film handling, accurate dosing, sealing consistency, and pod stability. The required conditions should always be validated with the selected film, formulation, and production environment.
Before industrial production, manufacturers should validate film compatibility, cavity geometry, dosing behaviour, sealing performance, pod integrity, dissolution requirements, and product stability. Trials should also confirm the expected output, reject levels, cleaning process, and changeover requirements. Testing the complete package and process under representative conditions reduces scale-up risk and helps define reliable operating parameters before regular production begins.
Water-soluble unit-dose packaging is particularly relevant for applications that require accurate dosing, controlled product handling, and reduced contact with concentrated formulations. Potential sectors include home care, industrial cleaning, water treatment, agrochemicals, personal care, and selected food or nutritional applications. Suitability depends on the formulation, film compatibility, regulatory requirements, storage conditions, and the expected behaviour of the package during use.
Tell us your formulation, pod design and output. Our team will define the right Hydroforma solution.
