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Rethinking Spare Parts

Greiner Packaging produces millions of food packaging units every day while also meeting stringent efficiency and availability requirements. Whenever it needed important machine components, the company had previously relied on expensive original parts with long delivery times. Greiner collaborated with the SFS Group to develop a 3D-printed alternative. The result: significantly lower costs, faster availability and greater operational flexibility.

Added value


  • Significant cost reduction thanks to cheaper spare parts and minimized machine downtime
  • Shorter delivery times and fewer dependencies in the supply chain
  • More reliable production thanks to practical solutions
  • Effective teamwork results in smooth processes

At the Greiner Packaging site in Diepoldsau (Switzerland), the machines of a single department process around three million cups a day. Production facilities work at near capacity, meaning that outages cost both time and money. That makes stable processes and quick spare part availability crucial.

Situation at the Outset: Expensive and Inflexible
Segmentation is a key production step: A cardboard sleeve is placed around the cup for further processing, which involves the use of gripper arms, folding fingers, and more. It used to be that these parts had to be procured as original spare parts – which are expensive and have long delivery times. A gripper arm costs around CHF 900, with simpler variants still costing several hundred francs. If machines or spare parts malfunction, this could cause delays or even stoppages in a worst-case scenario.

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L to R: Previous original spare parts from Greiner (1–2), prototype development at SFS (3–5), final version with 3D-printed sealing ring (6)

Finding a Solution Together
Greiner was looking for a more economical and flexible alternative. Existing contacts led to the collaboration with SFS and Hoffmann Additive Manufacturing (formerly Jellypipe AG), a company that has been part of the SFS Group since 2025. Keys to this project’s success were not only the spare part’s low price, but also the close, solution-oriented collaboration. Together, the companies redeveloped, tested and optimized the component. Challenges were resolved step by step – through direct communication between the teams.

Christian Paul Technical Manager Thermoforming at Greiner Packaging Ltd
“For us, the decisive factor wasn’t just the price, but especially the reliable support and excellent collaboration. Together, we developed a solution that makes our production line more flexible and reduces downtime.”
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Technically Sophisticated Implementation
The project began with an existing component that was redesigned in terms of its function, geometry and material. The aim was to create a robust overall solution for day-to-day production work. Designing the vacuum channels in the gripper arms was particularly challenging: They needed to function reliably, supply enough air, and at the same time prevent powder residues from entering the machine. Leak-tightness also played a key role. The geometry was continuously optimized until the components were capable of withstanding the high operational demands.

Material and Design as Success Factors
The material currently being used is PA12, an engineering plastic characterized by high strength and resistance and that is suitable for food production. Hygiene aspects were also taken into account: Grey components make dirt caused by white glue more visible. Certain parts were also designed with predetermined breaking points: In the event of a malfunction, they fail in a targeted manner, thereby protecting more sensitive components – a clear advantage in terms of operational reliability.

Measurable Added Value in the Company
The impact is clear: A 3D-printed gripper arm now costs around CHF 20 instead of around CHF 900. At the same time, the delivery time has been reduced from several weeks to roughly ten days. This not only reduces costs, but also dependency on supply chains. Production is becoming more flexible, responsive and more resistant to disruptions.

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Flexibility for Further Applications
Another advantage is the high degree of design freedom, since adaptations to new formats or requirements can be implemented quickly. For Greiner, that makes 3D printing more than a stand-alone solution. Other applications are already being examined – 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.

Contact & Services

Marcel Jordan