Flow Wrapper

Horizontal form fill and seal machines are often referred to as HFFS machines. HFFS machines come in different styles. Here, we examine HFFS flow wrapper machines.

Flow wrapper machine

Flow wrapper machines are a subset of horizontal form-fill-seal (HFFS) machines. They  are used in packaging to enclose products in a sealed film. The largest deployment of these machines are baked goods, candy bars and protein bars. Most of these products are made on flow wrappers. The main function of these machines is to provide a protective, tamper-evident, and often visually appealing package for products. There are a variety of machines with designs to handle different types of products. Some of the differences to keep in mind when looking at flow wrappers include min and max size of the product, product size consistency, production rates, hermetic seal requirements, gas flush and more. You should discuss the product and film requirements with a knowledgeable representative or integrator when considering a purchase.

Basic Operation

Film Feed: A roll of packaging film is fed into the machine. This film is typically made of materials like plastic, aluminum, or composite materials. Different films will require different temperatures and well time to get optimal seal.

Forming: The film is unwound and formed into a tubular shape around the product and the tube is made on a forming box. Forming boxes can be fixed or adjustable for different sizes. Fixed forming boxes create a consistent set up and reduce change over time. Adjustable forming boxes allow the operator to run a variety of sizes on the same former but require knowledge for correct set up.

Infeed: The product is placed on an infeed section which transfers it into the forming area. Infeed systems can be hand placed product or an automated infeed function that positions the product info the forming section.

Sealing: The film is sealed around the product, usually through a combination of heat and pressure. The three elements that can be managed on the machine are temperature and pressure to optimize the film seal. Film quality and composition has a large impact on the quality of film seals as well.

Cutting: The sealed film is cut to the desired length with a knife and anvil set which can create different seal patterns and types of cuts to the film.

Types of Packages produced on Flow Wrapper Machines

Pillow Pack Wrappers

Operation: A type of horizontal flow wrapper that creates a simple pillow-shaped package by sealing the film on the sides and ends.

Advantages: Cost-effective and straightforward design. Often used for single-serve products or small items.

Gusseted Flow Wrappers

Operation: These machines create packages with expandable sides, known as gussets, allowing for more space and flexibility in packaging.

Advantages: Useful for packaging bulky or irregularly shaped products. Provides extra room for products and can improve the visual appeal.

Shrink Wrapping Machines

Operation: After the product is wrapped, it is passed through a heat tunnel that shrinks the film tightly around the product.

Advantages: Provides a tight, tamper-evident seal and is suitable for various product sizes and shapes. Often used in conjunction with flow wrappers for added security.

Key Considerations

Product Type and Size: The choice of flow wrapper depends on the product’s size, shape, and packaging requirements.

Speed and Efficiency: Consider the required packaging speed and whether the machine needs to integrate with other production equipment.

Film Type and Material: The type of film used can affect the machine’s performance and the quality of the final package.

Film Material: The choice of film material affects the package’s durability, appearance, and sealing properties. The film should be chosen based on the product’s shelf life and protection needs.

Integration Partner Selection: Finding the right integration partner is a key to success for your packaging automation project. Right Stuff Equipment will help you with the right solution.

An example of an automated packaging line with a flow wrapper is shown below with additional equipment before and after the flow wrapper. An experienced integrator from Right Stuff Equipment can help you select the right packaging equipment to deliver a balanced line right for your needs. Email or call 303-327-4704.

Integrated flow wrapper machines will normally incorporate additional equipment to create a turn-key packaging line. Right Stuff Equipment can provide the turnkey system for your facility. Email or call us at 303-327-4704.

Marking and Coding: Incorporated into flow wrapper to track lot numbers, batch codes and expiration dates. Codes are used increasingly for track and trace requirements. A variety of coding options are available on flow wrappers. CIJ, Thermal Transfer, and Laser are most common. Right Stuff Equipment will help you identify the right identification system for your application.

Inspection: These can include metal detection, check weigh, X-Ray or vision to identify products or packaging that does not meet quality standards. Many of the larger retailers are requiring X-Ray inspection for food products. A letter from Costco is a prominent example.

Feeders: There are many feeders for flexible film packaging equipment. Sorting equipment, singulation and chicaning conveyors are all used to deliver the product to the wrapper to facilitate high speed flow wrapping when an automated infeed set is included with the flow wrapper.

Cartoning equipment and Case Packing equipment: Usually consists of loading the wrapped pieces into cartons or master cases.

Robotic Palletizing: Robots have taken a large part of the palletizing automation market share. The advantages include reliability, performance and competitive pricing.

Considering your options for packaging automation? Contact Right Stuff Equipment at 303.327.4704, or Email Us for more information.