VFFS Packaging Machine Working Principle

In modern industry packaging, there is no scope but efficiency and correctness. The most ubiquitous of today's most utilized package machines is the Vertical Form Fill Seal or VFFS machine. The highly automated package is of tremendous value in package manufacturing of food, pharmaceutical, and industrial products, making quick and cost-saving processes possible. This article takes a closer look at the working principle of VFFS packing machines, their components, applications, and key factors to consider when choosing one. Additionally, we will highlight Kenwei’ s advanced VFFS packaging solutions and their role in optimizing production efficiency.

What is a VFFS Packaging Machine?

A Vertical Form Fill Seal (VFFS) is an automated package system used to efficiently package products of various natures into bags or pouches. It makes a bag out of a roll of film, fills it with a product, and seals it vertically in one movement.

A VFFS packing machine accomplishes this by taking a flat roll of package film, making it into a vertical tube, closing off its seams, filling its formed bag with product, closing it up to make it into a finished package, and repeating this process efficiently and accurately, making it ideal for mass manufacturing.

A typical vertical form fill and seal machine consists of many key pieces of equipment

• Film Roll:  The operation is started by a roll of elastic packaging film that is continually fed into the system.
• Forming Tube : It transforms the plane film into a tube shape, making it appropriate for filling.
• Sealing Jaws: Ultrasonically or thermally seal the film edges together to make a rigid package.
• Filling Mechanism : Fills product into the bag through a controlled fill rate.
• Cutting Mechanism :  Cuts through every package upon closing
• Sensors and Control Systems : Ensure perfect alignment, sealing, and filling to preclude wastage of material and ensure maximum efficiency.

How Does A VFFS Machine Work?

Most businesses employ vertical form fill packaging because it is cost-effective and efficient and preserves valuable floor space. The packaging turns a roll of packaging film into finished, sealed bags very efficiently—up to 160  bags per minute, actually.

Each process has precise mechanisms to ensure correctness and efficiency. We describe each stage in greater detail below.

◆ 1. Film Transport & Unwinding

Vertical form fill and seal machines begin with a large roll of packaging material, known as roll stock, mounted on a spindle assembly at the rear of the machine. The material, called the film web, can be polyethylene, cellophane laminates, foil laminates, or paper laminates.

As the machine operates, film transport belts pull the film from the roll, guiding it to the forming tube at the front of the machine. Some models use sealing jaws instead of belts for film transport. A motor-driven surface unwinds wheel (power unwind) for heavy film rolls assists in unwinding, ensuring smooth operation.

◆ 2. Film Tension Management

During transport, the film passes over a dancer's arm, a weighted pivot arm equipped with rollers. This system maintains consistent film tension, preventing misalignment as the film moves through the machine.

◆ 3. Optional Printing

If required, the film then moves through a printing unit that can be thermal or ink-jet. The printer applies date codes, registration marks, logos, or other essential details on the film before forming the bag.

◆ 4. Film Tracking & Positioning

Next, the film travels past a registration photo-eye that detects printed registration marks, ensuring precise positioning and correct cutting. Additionally, film tracking sensors monitor film alignment and adjust the film carriage as needed to maintain proper positioning.

◆ 5. Bag Forming

The film is guided over the forming tube’s shoulder (collar), folding it into a cylindrical shape with overlapping edges. A vertical seal is then applied to bond these edges together, forming the bag. The seal can be a lap seal (overlapping edges for a flat seam) or a fin seal (sealed along the inner edges, creating a raised seam). A rotary encoder measures the film’s movement and signals the system to stop or continue based on the set bag length.

◆ 6. Bag Filling and Sealing

Once the bag is formed, the machine applies heat to create a vertical seal along the overlapping edges. Intermittent machines briefly pause for sealing, while continuous machines seal without stopping.

Next, horizontal sealing jaws close to form the top seal of one bag and the bottom seal of the next. Some continuous motion machines use dual sets of jaws for increased speed. Ultrasonic sealing can be used for heat-sensitive products, which bond the layers through high-frequency vibrations instead of heat.

While the sealing jaws are closed, the product is dispensed into the bag through the hollow forming tube. This is done using a filling system such as a multi-head scale or auger filler, which must be purchased separately from the VFFS packing machine.

◆ 7. Bagging Discharge

Once the product is inside, a cutting knife within the horizontal jaw cuts through the bag. After it is filled and sealed, the bag is dropped onto a container or conveyor. It can then continue to additional packaging processes such as weighing, X-ray inspection, or cartooning.

These machines automate package processes, offering rapid throughput, precise filling, and assured closing, making them an integral part of modern package technology.

Advantages of using a VFFS Packaging Machine

VFFS machines have many benefits that make them very popular among most industries.

● High-Speed Operation

Vertical form fill and seal machine can produce hundreds of packages per minute, significantly reducing packaging time and increasing production output.

● Versatility in Packaging of Various Materials

These machines can handle package materials ranging from plastics to laminated film, including biodegradable products, making them appropriate for use on diverse products.

● Cost-Effectiveness in Large-Scale Production

By automating packaging, vertical form seal machines save on labor costs, reduce wastage of material, and make processes more efficient, leading to lower overall manufacturing costs.

Factors to Consider When Buying a VFFS Machine

Selecting the right vertical form fill and seal machine is dependent on many factors, including

• Material Compatibility and Sealing Technology -  Packaging materials have specialized sealing processes that must be utilized to make the package resilient.
• Production Speed and Packaging Options - The machines have differing levels of speed capacities and package options; selecting one that suits production requirements is critical.
• Product Type and Filling Accuracy – Consider how accurately the machine fills, powders, or solids through its fill mechanism
• Integration with Current Systems - Being interoperable with existing manufacturing lines and automation devices increases workflow productivity
• Maintenance and Support - Easy to maintain and reliable tech support means that downtime is minimized along with operational disruptions

Kenwei’ s Advanced VFFS Packaging Systems

Kenwei offers top-of-the-line Vertical Form Fill Sealing (VFFS) solutions for maximum accuracy and efficiency. The machinery weighs seals, packs, and fills and can best use industrial goods, drugs, and foods. With its best-quality multi-head and linear weighers, Kenwei provides maximum accuracy, maximum speed, and minimum waste.

The vertical form fill and seal machines can be equipped with varying forms of packaging and different packaging materials, with individual solutions for individual industries. Built with strong stability and durability, they enhance production efficiency and cost-effectiveness.   Kenwei's easy-to-handle and modular design and intuitive interfaces facilitate easy use  and professional after-service guarantee customer satisfaction.

Conclusion

Investing in a VFFS packaging machine is a strategic choice for companies looking to enhance their packaging process, lower expenditure, and improve product quality. With advantages including its capacity for high-speed performance, flexibility, and automation, VFFS machinery simplifies the packaging process for different industries.  For businesses that demand reliable, top-performance package solutions, Kenwei ’s cutting-edge VFFS machines boast industry-leading technology and custom options to meet unique package specifications. Contact Kenweigh today to discuss their range of VFFS packing machines and take your package operation to new heights.