How Do Vertical Form Fill Seal (VFFS) Packaging Machines Work ...

Economical and efficient packaging solutions using film-formed bags, along with the compact and space-saving nature of VFFS machines, have made them widely applicable across various industries. 

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Do you want to understand how Vertical Form Filling Machines work? Would you like to learn about the functions and features of the components of VFFS Machines? In this article I will introduce you to the packaging process of the Vertical Form Filling Machines, from the rolled film to the finished bag.

Vertical Form Fill and seal Machine working principle

The Vertical Form Fill and Seal Machine, also known as a collar type filling and sealing packaging machine, is suitable for packaging various materials such as granules, powders, liquids, and pastes in pouches. The machine forms rolls of plastic film into bags, then measures the predetermined weight or volume of the product using a metering system before sealing the bag, creating a complete package.

Film Unwinding / Film Pulling

Roll film is unwound through an external film release device and pulled by a servo motor conveyor belt.

• Automatic film alignment function: The machine automatically adjusts the film to ensure proper alignment and prevent packaging misalignment.
• EPC (Edge Position Control): The EPC system is used to adjust the center alignment of the film. Pressing the “left” or “right” key moves the film frame to adjust the position of the film, aligning it with the center of the former.
• Control panel: Operators can adjust the tension and tracking of the film through the touch screen to ensure correct unwinding of the film during the forming process.

Code Printing

The coder is suitable for plastic film, PP, OPP, paper bags, labels, etc., integrated into VFFS machines to print batch numbers, production dates, and expiration dates on the film as it passes through the machine.

#1 Set the horizontal and vertical sealing bars, as well as the date coder, to the required temperature to ensure that the ink adheres correctly to the packaging material.

#2 Synchronize the printing speed of the coder with the packaging speed of the machine.

Bag Length Setting

Set the target bag length through the control panel, adjust the servo motor drive speed to pull the film. When setting the bag length on a VFFS machine, the following factors need to be considered:

Choosing Film Positioning Method:

Film Positioning has two options selectable on the touch screen: color mark length (photo-electric eye) and encoder length.

Color mark length (photo-electric eye):

Usually, printed films have color marks on them. The photo-electric eye detects these color marks on the film. The bag length is determined by the distance between color marks. The cutting position of the film can be adjusted based on the color mark points to avoid cutting into the printed design.

Encoder length:

Choosing encoder length allows direct modification of the packaging length on the screen. The length is detected as it scrolls, immediately changing the size of the bag produced (changing the bag width requires changing the forming unit). The length of the cut film is correct, but the cutting position cannot be adjusted, which may result in cutting into the printed design of the film.

First and Second Pull Film

When the bag needs to stretch the film twice, set the second stretch length here (total stretch length = first stretch length + second stretch length).

Consider Film Resistance

There is frictional resistance between the film and the machine, which affects the actual packaging bag length. (Thicker films have greater resistance).

If the packaging bag length does not reach the set accurate length, adjust the correction data until the desired true length is achieved.

Material Elevating / Weighing 

VFFS packaging machines are equipped with lifting systems and measuring systems for material lifting and weighing.

Material Lifting System:

Transports the packaged material from the ground to the weighing hopper above the packaging machine. It can be divided into granular, powder, and liquid/paste types.

Granular material: Z-type elevator, Large slanting elevator, single-bucket elevator, bucket elevator

Powder material: screw elevator, vacuum elevator

Material Weighing System:

The material is lifted to the hopper and measured according to the set packaging weight.

The most commonly used measuring systems are:

Combination scales (for weighing granular, flake, block, and strip materials, including candies, cookies, coffee beans, chips, nuts, frozen foods, vegetables, etc., with fast speed and accurate measurement).

Screw metering machines (for powders such as flour, coffee powder, protein powder, additives, etc.).

2-head/4-head/6-head linear scales (for fine granules or coarse powders, rice, sugar, salt, laundry detergent, coffee powder, with a wider measurement range than combination scales, acceptable accuracy, slightly slower speed than combination scales, tailored to different materials).

For liquids or pastes, piston filling machines are used (or servo-controlled rotary pumps for high accuracy, wide range, fast speed, but higher price).

Bag Forming

After the film is unwound, it is stretched and cut according to the set bag length, and then formed into bags using different forming collar devices. Operators can change the width of the packaging bags by replacing different forming devices.

The edges of the film overlap vertically and are heat-sealed together to form the back seal of the packaging bag. Different back seal forms are available for selection through the settings of VFFS machines.

Bag Filling and Sealing

The dosing feeding system delivers materials into the packaging bag forming area. After the bag is filled, the sealing clamp seals the top of the bag, creating a top seal for one bag and a bottom seal for the next bag.

 Here are the characteristics of bag sealing:

• Adjustable sealing time and pressure settings of the sealing jaws ensure the quality of bag sealing.（The thickness of different films will affect the speed and effectiveness of film melting and sealing.）
• The heavy-duty jaw assembly is equipped with a buffer for shock absorption and noise reduction.
• The sealing station can independently adjust the temperature, which is crucial for controlling the sealing temperature for both horizontal and vertical seals. This is applicable to different types of heat-seal films. (For composite film sealing, constant temperature heating rods are used for sealing; PE film is sealed using instant heating of resistance wires, requiring precise temperature control—too high a temperature can melt PE film, while too low a temperature may result in inadequate sealing.)
• Optional features include edge folding device (creates folds on the packaging bag), punching device (butterfly holes, round holes, handle holes), and nitrogen flushing device (for product preservation).

Bag Output

The cutting device of the machine separates the sealed continuous packaging bags, and the cut packaging bags are transported via a conveyor belt to downstream equipment such as pallets, checkweighers, metal detectors, boxing equipment, etc.

Introduction to VFFS Machines

Vertical form, fill, and seal (VFFS) machines are a popular packaging solution in various industries. They automate the packaging process by creating bags, filling them with the product, and sealing them shut. This article will dive deep into the workings of VFFS machines and explore their various components, process, types, applications, and benefits.

Key Components of a VFFS Machine

A VFFS machine consists of several key components that work together to create, fill, and seal bags efficiently.

2.1 Film Transport System

The film transport system feeds the packaging film from a roll into the machine. It controls the tension and alignment of the film to ensure a smooth and precise process.

2.2 Forming Tube and Collar

The forming tube and collar shape the packaging film into a cylindrical tube. The collar wraps the film around the forming tube, ensuring the correct size and shape for the final bag.

2.3 Vertical Sealing System

The vertical sealing system seals the edges of the film to form a continuous tube. It uses heat or pressure to create a strong and reliable seal.

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2.4 Horizontal Sealing and Cutting System

The horizontal sealing and cutting system forms the top and bottom seals of each bag. It uses heat or pressure to create a seal and a knife or cutting mechanism to separate the individual bags.

2.5 Filling System

The filling system is responsible for dispensing the product into the bags. There are various filling systems, such as volumetric cup fillers and auger fillers, depending on the product type and requirements.

2.6 Control System

The control system monitors and manages the entire VFFS process. It ensures that all components are working in harmony and that the machine is producing consistent, high-quality packaging. Modern VFFS machines often feature touchscreen interfaces and advanced software for easy operation and monitoring.

Working Principle- How VFFS Machine Works

Let’s explore the VFFS process in detail, from the unwinding of the packaging film to the discharge of the finished bags.

3.1 Film Unwinding

The process begins with the film transport system unwinding the packaging film from a roll. The film is guided through a series of rollers to ensure proper alignment and tension control.

3.2 Film Guiding and Tension Control

The film is guided through the machine using a combination of sensors and rollers. Tension control is essential for maintaining the film’s position and preventing wrinkles or misalignment, which could lead to defective bags.

3.3 Film Forming

The film is then wrapped around the forming tube and collar to create a cylindrical tube. The size and shape of the forming tube determine the dimensions of the final bag.

3.4 Vertical Sealing

Once the film has been formed into a tube, the vertical sealing system applies heat or pressure to seal the overlapping edges together, creating a continuous tube.

3.5 Filling

The filling system dispenses the product into the formed tube. The type of filling system used depends on the product’s properties and desired packaging accuracy. Volumetric cup fillers and auger fillers are examples of commonly used filling systems.

3.6 Horizontal Sealing and Cutting

The horizontal sealing and cutting system creates the top seal of the current bag and the bottom seal of the next one. Simultaneously, a cutting mechanism separates the individual bags.

3.7 Discharge

The finished bags are discharged from the machine, ready for further processing or packaging.

Types of VFFS Machines: Comparing Pneumatic and Servo-Driven VFFS Machines

Understanding the differences between pneumatic and servo-driven VFFS machines can help businesses choose the right packaging solution for their needs. In this section, we will compare the advantages and disadvantages of these two types of machines.

4.1 Pneumatic VFFS Machines

Pneumatic VFFS machines use compressed air to power their sealing and cutting systems. They are reliable and cost-effective, making them a popular choice for small to medium-sized businesses.

Advantages of Pneumatic VFFS Machines

1. Lower initial cost: Pneumatic VFFS machines typically have a lower upfront cost compared to servo-driven machines, making them more accessible for businesses with limited budgets.
2. Simple operation: Pneumatic machines are relatively easy to operate and maintain, with fewer complex components than servo-driven machines.
3. Reliability: Pneumatic VFFS machines are known for their durability and reliability, providing consistent performance over time.

Disadvantages of Pneumatic VFFS Machines

1. Limited speed and accuracy: Pneumatic machines generally have lower production speeds and less precise control over sealing and cutting compared to servo-driven machines.
2. Higher energy consumption: Pneumatic VFFS machines require a constant supply of compressed air, which can lead to higher energy costs.
3. Less flexibility: Pneumatic machines may have limited capabilities when it comes to handling various packaging materials and formats.

4.2 Servo-Driven VFFS Machines

Servo-driven VFFS machines use electric motors for precise control of their sealing and cutting systems. They offer higher speed, accuracy, and flexibility, making them ideal for larger businesses and more demanding applications.

Advantages of Servo-Driven VFFS Machines

1. Higher speed and accuracy: Servo-driven machines provide faster production speeds and more precise control over sealing and cutting, ensuring consistent and high-quality packaging.
2. Greater flexibility: Servo-driven VFFS machines can handle a wider range of packaging materials and formats, making them more adaptable to different packaging requirements.
3. Energy efficiency: Servo-driven machines typically consume less energy than pneumatic machines, as they do not require compressed air to operate.
4. Improved automation and control: Servo-driven VFFS machines often feature advanced software and control systems, allowing for greater automation, monitoring, and customization of the packaging process.

Disadvantages of Servo-Driven VFFS Machines

1. Higher initial cost: Servo-driven VFFS machines generally have a higher upfront cost compared to pneumatic machines, which may be a barrier for some businesses.
2. Increased complexity: Servo-driven machines have more complex components, which can make them more challenging to operate and maintain.
3. Potential for higher maintenance costs: The advanced components and technology in servo-driven machines may lead to higher maintenance costs over time.

Packaging Materials and Formats

VFFS machines can handle a wide range of packaging materials and formats, including pillow pouch packaging and customized shaped bags.

5.1 Pillow Pouch Packaging

Pillow pouch packaging is a simple and cost-effective packaging format suitable for various products, including snacks, powders, and granular products.

5.2 Customized Shaped Bags

Customized shaped bags are an attractive option for businesses looking to stand out in the market. These bags can be designed to match the product’s shape, brand identity, or consumer preferences.

Applications of VFFS Machines

VFFS machines are widely used in various industries due to their versatility, efficiency, and cost-effectiveness.

6.1 Food Packaging

Food packaging is a common application for VFFS machines, as they can handle a wide range of products, including powders, liquids, and solids. They are used for packaging products like sugar, salt, spices, and more.

6.2 Coffee Packaging

VFFS machines are an ideal solution for coffee packaging, as they can create airtight seals to maintain freshness and accommodate various packaging materials, such as laminated films and foil.

6.3 Snack Food Packaging

Snack food packaging is another popular application for VFFS machines. They can efficiently package chips, popcorn, nuts, and other snack items in pillow pouches or customized shaped bags.

6.4 Pet Food Packaging

VFFS machines are also used in the pet food packaging industry. They can package various pet food products, including kibble, treats, and supplements, in a range of bag sizes and materials.

Different Filling Methods for VFFS Machines

VFFS machines can be equipped with various filling systems to accommodate different product types, ranging from liquids and powders to granules and solids. In this section, we will discuss the most common filling methods used in VFFS machines.

7.1 Volumetric Cup Filler

A volumetric cup filler is a filling system that uses a series of adjustable cups to measure and dispense products. This filling method is ideal for free-flowing granular products, such as rice, sugar, and seeds.

Advantages

1. Simple and cost-effective: Volumetric cup fillers are relatively simple in design and generally more affordable compared to other filling systems.
2. Easy to adjust: The volume of the cups can be easily adjusted to accommodate different product quantities.

Disadvantages

1. Limited accuracy: Volumetric cup fillers may not provide the same level of accuracy as other filling methods, particularly for products with irregular shapes or inconsistent densities.

7.2 Auger Filler

An auger filler is a filling system that uses a rotating screw or auger to dispense measured quantities of powders and granular products. This filling method is suitable for products such as flour, spices, and powdered milk.

Advantages

1. High accuracy: Auger fillers provide precise filling, ensuring consistent product quantity in each package.
2. Versatility: They can handle a wide range of product densities and particle sizes, making them suitable for various powder and granular products.

Disadvantages

1. Higher cost: Auger fillers can be more expensive than other filling methods due to their complex design and precision components.
2. Requires regular maintenance: The auger and other components may need frequent cleaning and maintenance to prevent product buildup and ensure accurate filling.

7.3 Piston Filler

A piston filler is a filling system that uses a piston to dispense measured quantities of liquid and semi-liquid products. This filling method is ideal for products such as sauces, dressings, and creams.

Advantages

1. High accuracy: Piston fillers provide precise filling, ensuring consistent product quantity in each package.
2. Versatility: They can handle a wide range of product viscosities, making them suitable for various liquid and semi-liquid products.

Disadvantages

1. Higher cost: Piston fillers can be more expensive than other filling methods due to their precision components and design.
2. Requires regular maintenance: The piston and other components may need frequent cleaning and maintenance to prevent product buildup and ensure accurate filling.

7.4 Combination Weigher

A combination weigher is a filling system that uses multiple weighing units to measure and dispense products. This filling method is suitable for a variety of products, including snack foods, candies, and frozen items.

Advantages

1. High accuracy and speed: Combination weighers provide precise filling at high speeds, ensuring consistent product quantity in each package and improving overall production efficiency.
2. Versatility: They can handle a wide range of product types, sizes, and shapes, making them suitable for various industries.

Disadvantages

1. Higher cost: Combination weighers can be more expensive than other filling methods due to their advanced technology and precision components.
2. Requires regular maintenance: The weighing units and other components may need frequent cleaning and maintenance to ensure accurate filling and prevent product buildup.

Choosing the Right VFFS Machine for Your Business

Selecting the right VFFS machine for your business depends on several factors, including the product type, packaging materials, production speed, and budget. For more information on choosing the right packaging machine, visit this guide.

Benefits of VFFS Machines

VFFS machines offer numerous benefits, including:

1. High efficiency: VFFS machines automate the packaging process, significantly increasing production speed and reducing labor costs.
2. Versatility: They can handle various packaging materials, formats, and product types, making them suitable for a wide range of industries.
3. Cost-effectiveness: VFFS machines provide an affordable packaging solution that offers a quick return on investment.
4. Reliability: Modern VFFS machines are designed for long-lasting, reliable performance with minimal downtime.

In-House vs. Contract Packaging

When deciding between in-house packaging using a VFFS machine or outsourcing to a contract packager, businesses must consider factors such as production volume, cost, and control over the packaging process. For more information on the pros and cons of each option, visit this guide.

Conclusion

VFFS machines are a versatile and efficient packaging solution suitable for various industries. Understanding their components, process, types, and applications can help businesses select the right machine for their needs and leverage the many benefits of automated packaging.

FAQs

Q1: What is a VFFS machine?

A: A VFFS (Vertical Form, Fill, and Seal) machine is an automated packaging machine that creates bags from a roll of film, fills them with the product, and seals them shut.

Q2: What are the key components of a VFFS machine?

A: The key components of a VFFS machine include the film transport system, forming tube and collar, vertical sealing system, horizontal sealing and cutting system, filling system, and control system.

Q3: What types of products can be packaged with a VFFS machine?

A: VFFS machines can package a wide range of products, including food items, coffee, snacks, pet food, and more.

Q4: What are the main types of VFFS machines?

A: The main types of VFFS machines are pneumatic and servo-driven machines.

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Q5: What are the benefits of using a VFFS machine for packaging?