A New Approach to Replacement Parts
Greiner Packaging produces millions of food packaging units every day, meeting the highest standards for efficiency and availability. Until now, the company had to rely on expensive original parts with long lead times for key machine components. Together with the SFS Group ,Greiner developed a 3D-printed alternative. The result: significantly lower costs, faster availability, and greater operational flexibility.
Added Value
- Significant cost savings through lower-cost replacement parts and minimized machine downtime
- Shorter delivery times and fewer dependencies in the supply chain
- Greater production reliability through practical solutions
- Effective teamwork leads to smooth processes
At Greiner Packaging’s facility in Diepoldsau, Switzerland, the machines in a single department process approximately three million cups per day. Production runs at full capacity—downtime costs both time and money. Consequently, stable processes and readily available replacement parts are crucial.
The Situation: Expensive and Inflexible
A key production step is segmentation: a cardboard sleeve is placed around the cup and further processed. This process involves the use of gripper arms and folding fingers, among other components. Until now, these parts had to be procured as original replacement parts—which were expensive and had long lead times. A gripper arm costs around CHF 900; even simpler versions cost several hundred francs. Defects in the machine or a spare part threatened to cause delays or, in the worst case, production stoppages.
Working Together Toward a Solution
Greiner was looking for a more cost-effective and flexible alternative. Through existing contacts, a partnership was formed with SFS and Hoffmann Additive Manufacturing (formerly Jellypipe AG), a company that has been part of the SFS Group since early 2026.
The decisive factor was not only the low price of the replacement part, but also the close, solution-oriented collaboration. The component was jointly redesigned, tested, and optimized. Challenges were resolved step by step—through direct communication between the teams.
Christian Paul, Technical Manager of Thermoforming at Greiner Packaging AG
"For us, it wasn't just the price that was decisive, but above all the reliable support and the good working relationship. Together, we developed a solution that makes our production more flexible and reduces downtime."
Technically Sophisticated Implementation
The starting point was an existing component that was redesigned in terms of function, geometry, and material. The goal was a robust overall solution for everyday production.
The design of the vacuum channels in the gripper arms was particularly challenging: They must function reliably, deliver sufficient airflow, and at the same time prevent powder residue from entering the machine. Leak-tightness also played a central role. The geometry was continuously optimized until the components could withstand the high demands of operation.
Material and Design as Factors for Success
PA12 is used today—an engineering plastic with high strength and durability that is suitable for food production. Hygiene considerations were also taken into account: Gray components make contamination from white glue more visible. In addition, certain parts are designed with defined predetermined breaking points: In the event of a malfunction, they yield in a controlled manner, thereby protecting more sensitive components—a clear advantage for operational safety.
Measurable Added Value in Operation
The impact is clear: A 3D-printed gripper arm now costs around CHF 20 instead of the previous price of around CHF 900. At the same time, the lead time is reduced from several weeks to about ten days. This not only lowers costs but also reduces dependence on supply chains. Production becomes more flexible, more responsive, and more resilient to disruptions.
Flexibility for Additional Applications
An additional advantage is the high degree of design freedom, as adjustments to new formats or requirements can be implemented quickly. For Greiner, 3D printing is therefore more than just a one-off solution. Additional applications are already being evaluated—ranging from assembly aids to complex functional parts. This successful collaboration demonstrates how additive manufacturing can be integrated in a practical way and create sustainable added value.
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Onur Yildirim
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