International Travel Medicine Center of Iran International Journal of Travel Medicine and Global Health 2322-1100 14 2 2026 07 01 Ensuring Traveler Health Through Single-Serve Instant Beverage Packaging: Optimization of Sachet-Filling Parameters for Product Safety and Quality Preservation 119 127 243280 10.30491/ijtmgh.2025.542532.1502 EN Sayyed Mohammadreza Sedehi School of Mechanical Engineering, College of Engineering, University of Tehran, Tehran, Iran Abdolah Alinejad Research and Development Manager, San Faravar Sepehr Manufacturing Group (Bargaz), Gonabad, Iran Narges Dehghanniri Master of Health, Safety and Environmental Management (HSE), Environmental Health Expert, Yazd City Health Center, Health Assistant, Shahid Sadoughi University of Medical Sciences, Yazd Motahareh Sadat Dehghan Niri Faculty of Engineering, University of Gonabad, Gonabad Niloofar Darroudi Faculty of Engineering, University of Gonabad, Gonabad Journal Article 2025 08 20 Objectives: This study was conducted to ensure traveler health and food safety by investigating the effects of key sachet-filling machine parameters on the quality and safety of single-serve instant beverage packaging.<br>Methods: Three main variables were examined under controlled experiments: metallized film thickness (55, 75, and 95 μm), sealing temperature (125, 135, and 145 °C), and filling speed (slow, medium, and fast). Evaluations focused on three critical indicators package distortion, adhesion to the cutter, and seal integrity—to establish optimal conditions that ensure product safety and maintain packaging quality for single-serve use.<br>Results: Increasing metallized film thickness from 55 to 95 μm reduced adhesion to the cutter but led to higher package distortion. Higher sealing temperatures (145 °C) improved adhesion, yet, when combined with higher filling speeds, seal integrity deteriorated. Optimal conditions were identified at 75 μm thickness, 135 °C sealing temperature, and medium filling speed, which minimized distortion and adhesion while ensuring high-quality sealing and safe single-serve packaging.<br>Discussion: These findings emphasize the importance of simultaneous optimization of machine parameters to enhance packaging quality and safety in single-serve instant beverage production. The results provide a reliable basis for designing industrial processes that prioritize product safety, minimize health risks for travelers, and ensure consistent packaging performance https://www.ijtmgh.com/article_243280_5c5d387e3261414e89596ad964c99443.pdf