Tailored machinery provider Rychiger explores the production challenges companies packing coffee capsules face and the new solutions it’s bringing to market.
The coffee capsule market is a crowded one, with a multitude of options for consumers to choose from when browsing the supermarket shelves. Yet, according to Beatriz Perroud, Senior Sales Manager at Rychiger, there are three key ways capsule producers can get ahead of the competition.
“The main challenge faced by capsule producers is offering a wide variety of aromas and designs while keeping production cost low – despite the high flexibility required,” says Perroud.
“However, the good news is there are solutions to make producers stand out from the crowd. To keep aroma locked into the capsule, excellent sealing is required. In terms of design, the look and feel of the capsule matters, with diversity being a key market driver.
“And to keep production costs down to deliver savings to the consumer, optimisation of material consumption and reducing operating and format-changeover times are essential.”
Rychiger’s filling and sealing machines are specifically developed to overcome these challenges. From high-precision sealing that preserves aroma and freshness to the ability to handle various formats and perform quick format changeovers, Perroud says the technology within the company’s modular solutions can be configured to match each customer’s specific requirements.
“Thanks to the flexible design and a wide range of options, we can tailor the machine to the required application,” she says.
“This approach gives our customers the reliability of a proven platform combined with the customisation needed for their unique products and processes.”
Rychiger recently launched its new FS 150 packaging machine, which has an output of up to 140 capsules per minute. Its sister FS 300 model, capable of reaching 280 capsules per minute, is due to be introduced to the market soon.
“The FS 300 is the first machine to include Rychiger EDGE as an enabler for future needs. The digital ecosystem provides customers with a comprehensive data platform to monitor and control the entire production line, enabling users to make decisions based on real-time data rather than relying on observation alone,” she says.
“The first FS 150 is already in successful production. For the FS 300 equipped with EDGE technology, we are opening up conversations with companies that would like to take advantage of these state-of-the-start technologies which are available for delivery from May 2026.”
Both machines have been developed for capsule producers and co-packers with small- to mid-size operations that require maximum flexibility in their packaging operations. With an increasing variety of capsule materials coming into the market driven by demand for sustainable options, producers want to be able to switch between products quickly with the shortest operational downtime.
Format changes on the new machines take between 15 and 90 minutes, depending on the complexity of the changeover. For example, they can be configured to produce Dolce Gusto capsules in the morning and Nespresso capsules in the afternoon. The required format change can be done during a lunch break, increasing both flexibility and productivity.
“Sustainable coffee capsules are gaining attention, but they still need time to become the industry standard,” says Perroud.
“Right now, most producers want to offer a sustainable option, but fully dedicating a production line to compostable capsules is something only few can afford. That’s why flexibility is so important – our machines allow producers to run different capsule types on the same platform.”
As part of Rychiger’s drive towards sustainability, the FS 150 has been developed to significantly reduce lid material and nitrogen consumption.
“This not only improves cost-efficiency but also supports sustainability. In addition, its smart design results in low maintenance costs, which is a clear win for operations and finance alike,” Perroud says.
“What’s more, the product is filled with exceptional precision, as each dosing station is driven by its own servo motor and directly weighed – with a continuous real-time feedback loop.
“Another highlight is Rychiger’s One-Stroke technology, which ensures lids are placed 100 per cent centrally on the capsules. This not only guarantees perfect sealing but also results in a visually appealing appearance. This market-leading technology guarantees consistently high-quality filling, punching, and sealing – with minimal rejects.”
With sustainability, cost, and quality covered, another element consumers look for when choosing a capsule is variety, specifically flavour.
“Our customers want flexibility in design and flavour to set themselves apart from the competition,” she says. “With the FS 150 and FS 300, capsules can be equipped with flavour dosing units. These enable production of various flavours such as vanilla for Dolce Gusto and caramel for Nespresso, all without the need for a changeover as the machine can be fitted with two independent dosing units.
“The FS 150 and FS 300 are more than just machines – they are solutions to manufacturers’ production challenges.”
For more information, visit rychiger.com
This article was first published in the September/October 2025 edition of Global Coffee Report. Read more HERE.
