Vertical Form Fill Seal Machine Guide: Everything You ...

What Pouch Styles Can VFFS Be Formed?

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VFFS machines can work with several pouch styles, a few of them are&#;

1. Pillow Bag:

   As the name suggests, these bags are

   pillow-shaped

   . They usually have a top and bottle seal, and their backside is sealed, making them easy to open. For their unique shape, they are also known as t-seal pouches. 

2. Gusset Bag:

   Often, a gusset bag comes with a side and bottom gusset to make more room for products. This feature makes them stand still on the shelves. So the customer notices the package and boosts sales.

3. 3-sided Seal Bag:

   VFFS machines also work with a

   3-sided seal bag

   . Typically, these pouches are sealed on two sides and the bottom. They left the top open so it would be easy to tear up. If you want to pack a small amount, use a three-sided sealed bag. 

4. 4-sided Seal Bag:

   These bag types are ideal for single-serve products. With

   four-sided seals

   , they become flat and can store tiny products, making them easy to carry. 

5. Stick Pack:

   With long and narrow shapes, they hold powder and liquid contents. These

   stick packs

   are perfect for sample and single-serve use.

Choosing The Right VFFS Machine For Your Business

 

You can choose the suitable VFFS device for your business considering a few factors mentioned below-

Product Types

Whether you have an industry for liquid, granule, or powder products, check that the machine can handle those products before purchasing one. Although the VFFS machine can also handle different materials, like plastic, foil, and even paper, it&#;s always best to ensure configuration. 

Packaging Speed 

Based on the model, these machines can fill bags ranging from 10 to 200 each minute. Depending on the demands of your business, choose between continuous or intermittent, multi-lane packaging or multi-packing machine.

Machine Size and Footprint

While selecting a VFFS machine, consider the space in your factory. For instance, the machine&#;s size and footprint must comfortably fit within your production area. Typically, the larger the packaging bag, the larger the VFFS machine will be, considering the height and footprint of the different lifting, weighing, and filling auxiliary machines.

Operator Skill Level 

VFFS machines are easy to operate, whether you are a first-time operator or an experienced expert, I am sure you will easy to operate a VFFS machine according to the operator&#;s manual and the manufacturer&#;s instructions.

Find a Reliable Manufacturer or Su

pplier

Finally, finding a reliable manufacturer or supplier is significant. They not only offer quality products but also ensure consumer support. Choose HonorPack to get high-quality VFFS machines. 

Identifying And Troubleshooting Common VFFS Machine Problems

 

Let&#;s take a look at some of the problems and troubleshoot ideas of the VFFS machine-

• Film Tracking Issues:

  Film tracing problems are often caused by the machine&#;s worn rollers, unaligned film, and improper tension. 

Solution: You should check the film and inspect the tension control. If you find any problems in these systems, fix them quickly. 

• Irregular Bag Lengths:

  Irregular bag lengths can result from inconsistent film feed or sensor malfunctions. The main causes are worn drive belts, incorrect sensor calibration, or film slippage. 

Solution: Inspect the drive belts for wear; if the belts are the problem, replace them immediately. Also, recalibrate the sensors and ensure the film is feeding consistently without slipping.

• Machine Downtime:

  VFFS downtime can result from mechanical failures, electrical issues, or improper maintenance. It will minimize your productivity. 

Solution: This problem can be avoided by regularly examining and servicing critical components like motors, belts, and sensors.

• Product Getting Caught in Seals:

  Does your VFFS machine often get its product caught in seals? This can be annoying when packaging, right? Products are usually caught in seals due to overfilling, improper timing, or product buildup.  

Solution: You must check and adjust the filling mechanism timing settings and ensure the sealing jaws are clean.

• Poor Seal Integrity:

  This problem in VFFS machines can lead to leaks and compromised product safety. Incorrect sealing temperatures, dirty sealing jaws, and misaligned films are common causes of poor seal integrity. 

Solution: Examine the temperature settings, clean the sealing components, and check the film is aligned correctly.

Conclusion

Still confused about VFFS machines and whether you should buy them? Well, let me clarify again: VFFS machines are among the most reliable machines for your industry, as they can help you to make several pouch styles and handle a wide range of products. It also ensures airtight seals, prevents products from mold, and keeps them fresh. 

Contact us to discuss your requirements of Small Vertical Form Fill Seal Machine. Our experienced sales team can help you identify the options that best suit your needs.

To get the best VFFS machine, contact HonorPack now. 

FAQs

What is the principle of the form fill seal machine?  

The principle of the form fill seal machine is to create the bag from the film into different sizes and shapes. Then, it fills the pouches with products and finally seals. Often, some machines come with features like print and weighing the amount of the product. 

What is the difference between hffs machines and vertical form fill seal machines?  

The critical difference between these two machines is their operating system. For instance, horizontal form fill seal machines package products lying horizontally. On the other hand, vertical or VFFS machines work vertically, which is best for packing grains and liquid contents. 

Can I pair my VFFS machine with just any film?

No, unfortunately, you can&#;t pair your VFFS machine with just any film. The film must be compatible with the machine&#;s sealing mechanisms, product type, and packaging requirements. If you use the wrong film, it can lead to poor seals, product damage, and machine malfunctions. 

Like any manufacturing business, the food packaging industry is always looking for the best ways to maximize efficiency while maintaining quality standards. Selecting the right equipment is essential to achieving these goals.

There are two main types of packaging machines: horizontal form fill seal (HFFS) machines and vertical form fill seal (VFFS) machines. In this post, we cover the differences between vertical and horizontal form fill systems and how to decide which is right for your business.

Main Differences Between Vertical and Horizontal Form Fill Seal Systems

Both horizontal and vertical packing machines improve efficiency and production speed in food packaging facilities. However, they differ in the following significant ways:

Orientation of Packaging Process

As their names indicate, the main difference between the two machines is their physical orientation. HFFS machines, also known as horizontal flow wrap machines (or simply flow wrappers), wrap and seal goods horizontally. By contrast, VFFS machines, also known as vertical baggers, package items vertically.

Footprint and Layout

Due to their horizontal layout, HFFS machines have a much larger footprint than VFFS machines. While you can find machines in different sizes, horizontal flow wrappers are typically much longer than they are wide. For example, one model measures 13 feet long by 3.5 feet wide, while another measures 23 feet long by 7 feet wide.

Suitability for Products

Another key difference between HFFS and VFFS machines is the type of products they can handle. While horizontal packaging machines can wrap everything from small objects to bulky items, they are best for single solid goods. For example, food packaging companies may choose HFFS systems for bakery products and cereal bars.

Vertical baggers, on the other hand, are better suited for items of varying consistencies. If you have a powder, liquid, or granular product, a VFFS machine is the better choice. Examples in the food industry are gummy candies, coffee, sugar, flour, and rice.

Sealing Mechanisms

HFFS and VFFS machines create a package from a roll of film, fill it with the product, and seal the package. Depending on the packaging system, you may see a variety of sealing mechanisms: heat seals (using electric resistance), ultrasonic seals (using high-frequency vibrations), or induction seals (using electromagnetic resistance).

Each seal type has its pros and cons. For example, a classic heat seal is reliable and cost-efficient but requires a cooling step and a larger machine footprint. Ultrasonic mechanisms create hermetic seals even for messy products while reducing packaging material consumption and sealing times.

Speed and Efficiency

While both machines offer high efficiency and strong packing capacity, horizontal flow wrappers have a clear advantage in terms of speed. HFFS machines can pack a large number of products in a short time, making them especially useful for high-volume applications. Servo drives, sometimes called amplifiers, enable HFFS machines to maintain precise control at high speeds.

Packaging Format

Both systems allow for flexibility in packaging formats, but horizontal flow wrappers permit a greater variety of types and closures. While VFFS machines can accommodate bags of multiple sizes and styles, HFFS machines can accommodate pouches, cartons, sachets, and heavier bags with nozzles or zippers.

Operational Mechanisms and Principles

Horizontal and vertical packaging machines have numerous similarities. Both are made of stainless steel, both are suitable for the food and medical industries, and both form, fill, and seal packages in one operation. However, their physical orientation and mode of operation differ.

Explanation of How Each System Operates

HFFS systems move products along a horizontal conveyor belt. To make the pouch, the machine unwinds a roll of packaging film, seals it at the bottom, and then seals it along the sides in the correct shape. Next, it fills the pouch through the top opening.

This stage may include hot fills for heat-processed products, clean fills for non-heat-processed goods, and ultra-clean fills for cold-chain distribution. Finally, the machine seals the product with the proper closure, such as zippers, nozzles, or screw caps.

VFFS machines work by pulling a roll of film through a tube, sealing the tube at the bottom to form a bag, filling the bag with the product, and sealing the bag on the top, which forms the bottom of the next bag. Finally, the machine cuts the bottom seal in the middle to separate the bags into individual packages.

A principal difference from horizontal machines is that vertical machines rely on gravity to fill the packaging, dropping the product into the bag from above.

Which System Requires a Higher Initial Investment: Vertical or Horizontal?

Whether you choose a vertical or horizontal packing machine, costs will vary depending on each system&#;s size, features, capabilities, and customization. However, most industry insiders consider VFFS the most cost-effective packaging solution. But that&#;s only true if they work for your product. In the end, the right system for you is the one that fits your needs and optimizes your production line.

What Are the Ongoing Maintenance Costs Associated With Each System?

Beyond the initial price, all packing systems require ongoing cleaning, maintenance, and repairs. However, VFFS machines also have the edge here, as they are less complicated and need less maintenance. Unlike horizontal packaging systems, vertical baggers can only form one package type and only have one filling station.

Factors Influencing the Choice Between Vertical and Horizontal Systems

When looking at vertical vs. horizontal form-fill systems, evaluating the following factors can help you choose the right one for your needs:

Type of Product Being Packaged

For starters, what types of products are you packaging? If you&#;re packing muffins, cakes, or candy bars, HFFS is ideal. However, if you manufacture pasta, spices, or chips, you may want to choose VFFS. Vertical baggers are typically better for anything difficult to handle manually, including liquids, loose items, and sticky or doughy products.

Production Volume and Speed Requirements

Although horizontal packaging machines cost more to purchase and run, they make up for this in production speed. If your business has high output demands and needs high packaging capacity, you can recoup your expenses quickly.

For example, high-speed HFFS systems can deliver 300 pouches per minute. Compared to pre-made pouches, the cost savings of HFFS film-roll pouches alone allow many businesses to cover their equipment costs in 12 to 18 months.

Standard VFFS systems, on the other hand, produce around 50-70 pouches per minute. You can purchase additional lanes to increase the output, but this may require a customized machine.

Available Space in the Production Facility

Due to their long, horizontal conveyor mechanism, flow wrappers take up a lot of space. If floor space is at a premium in your facility, you may look for more compact VFFS machines &#; as long as they&#;re compatible with your product type.

Budget Constraints

Given their complexity, high price point, and ongoing maintenance costs, HFFS machines are better suited to large-scale businesses with a high production output. Comparatively low-budget and low-maintenance, VFFS machines are often better for small and medium-sized businesses.

Can Both Vertical and Horizontal Form Fill Systems Be Automated?

Both HFFS and VFFS machines are assembly-line packaging automation systems designed to increase production speeds, lower labor costs, and reduce human error. They can automate the entire process, including weighing products, forming bags, filling pouches, and sealing individual packages.

Typically, these machines come in automated and semi-automated versions. Semi-automated horizontal systems typically require more manpower than semi-automated vertical baggers, which usually need only a single operator. Increasing automation, including robotics, will likely further streamline packaging in the future.

Common Challenges and Solutions of the Two Systems

Just as each packaging solution has advantages, each type of machine has challenges.

Maintenance Issues

Although horizontal systems typically require more maintenance than vertical systems, both types of machines suffer from periodic problems. For example, the film may not track properly, the product may get trapped in the seal, or bag lengths may vary widely.

Solutions to these issues include investing in operator training, conducting preventative maintenance and cleaning, and knowing when to call a professional for assistance.

Product Changeovers

Whenever you are changing machines to accommodate different packages or products, production often comes to a halt. A faster changeover means increased efficiency and more money in your pocket.

No matter which type of machine you choose, look for one that facilitates easy and quick changeovers. Some HFFS machines even come with two forming stations and two sealing stations so that you can change from one sized package to another automatically with zero downtime.

Operator Training and Skill Requirements

HFFS machines are larger, have more complexity, feature multiple filling stations, and produce more than one type of packaging. As a result, they often require higher levels of operator training and skill. In contrast, most VFFS machines have a user-friendly control panel that even first-time operators can usually easily understand.

What Packaging Automation Solution Is Right for You?

If you&#;re still wondering about vertical vs. horizontal form fill systems, contact the experts at TDI Packsys today. We offer a range of HFFS and VFFS systems to meet your needs, plus expert guidance to help you choose the right one.

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