At interpack 2026, GEA will launch the PowerPak 5000, a new thermoforming packaging machine for medium-sized food producers that need several different pack sizes, reliable daily operation, and scalable automation in the mid-size performance range.

GEA’s new PowerPak 5000.

The new model has been developed as a broadly applicable solution for the majority of thermoforming use cases, with emphasis on repeatable output, ease of operation, and predictable lifecycle costs.

Centralized operation and digital support in line production

The machine is equipped with GEA SmartControl, the company’s control interface for operation and monitoring. Operator can use a centralized human-machine interface, or HMI, to manage machine settings, production status, and process adjustments. These intend to reduce dependence on highly specialized labor and support more consistent machine performance even when staffing structures change.

PowerPak 5000 is also paired with GEA’s condition monitoring system GEA InsightPartner for continuous observation of machine status data, such as component behavior, temperature, or operating patterns, to identify potential issues at an early stage and support planned maintenance rather than reactive repair. These improve uptime and maintenance planning in plants, enhancing line efficiency and delivery performance.

New InsightPartner Notification Service and its accompanying Mobile App provide a fully integrated solution for delivering real time machine notifications directly to users. The system enables operators to configure and receive targeted alerts on alarms, KPIs, and maintenance requirements, ensuring faster reaction times, reduced downtime, and improved overall equipment availability.

With GEA Changeover Assist, GEA introduces an innovative digital solution that guides machine operators— even those without extensive machine expertise—safely and efficiently through every product changeover. The system provides step by step instructions, visual guidance, and intelligent checklists to ensure that all required adjustments and component changes are completed correctly.

Modular expansion for changing production requirements

A key aspect of the new machine is its modular design. The solution can be expanded with advanced technologies as production requirements change, these options include PowerHeat, PowerJet, and PowerLabel technologies.

PowerHeat is a heating system for thermoforming applications and is designed to improve heating efficiency, particularly when processing mono-materials. It can reduce energy consumption by 25-30% in relevant mono-material applications. PowerJet is an evacuation and gassing system, which supports pack atmosphere control during vacuum and MAP processes. PowerLabel is a modular labeling concept previously available primarily on larger GEA thermoforming systems.

Multiple packaging formats on one platform

The machine supports a broad packaging range, including MAP, vacuum, skin, and steam applications. It also addresses applications in meat and poultry, fish and seafood, cheese and dairy, bakery, ready meals, and plant-based food categories.

By covering these formats on one machine, the PowerPak 5000 is designed to help processors manage multiple product categories while simplifying product and format changes.