In the realm of packaging machinery, vertical packing machines play a pivotal role in efficiently packaging various products. From food to pharmaceuticals, these machines provide a streamlined approach to packaging while maintaining precision, speed, and dependability. However, investing in a vertical packing machine requires careful consideration to ensure that it aligns with your specific requirements and business objectives. In this article, we delve into the essential factors to ponder before making a purchase decision.
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Understanding Vertical Packing Machines
Before delving into the considerations, let’s briefly understand what vertical packing machines are and their significance in the packaging industry.
Vertical packing machines, also known as vertical form fill seal (VFFS) machines, are automated packaging systems primarily used to package solid products such as granules, powders, liquids, or pastes. These machines create packages from a flat roll of packaging material, fill them with product, and then seal them vertically. The versatility and efficiency of vertical packing machines make them indispensable in a wide range of industries, including food and beverage, pharmaceuticals, cosmetics, and more.
Factors to Consider Before Buying a Vertical Packing Machine
Packaging Requirements and Product Characteristics
Before purchasing a vertical packing machine, it's crucial to assess your packaging requirements and the characteristics of the products you intend to package. Consider the product's size, shape, weight, and consistency. Different items may necessitate specific packaging materials and configurations, and the machine should be able to accommodate these differences. For instance, delicate products may necessitate gentler handling mechanisms to prevent damage during the packaging process.
Packaging Speed and Output
The packaging speed and output capacity of the vertical packing machine are critical considerations, especially for high-volume production environments. Evaluate your production requirements and specify the desired packaging pace in packages per minute (PPM) or units per hour. Ensure that the machine's speed capabilities align with your production targets to avoid bottlenecks and inefficiencies in the packaging line.
Packaging Material and Film Type
Vertical packing machines are compatible with various types of packaging materials, including polyethylene (PE), polypropylene (PP), laminates, and more. The choice of packaging material depends on factors such as product characteristics, shelf life requirements, and aesthetic preferences. Additionally, consider the type and quality of the film used for packaging, as it can impact the overall appearance, durability, and preservation of the packaged products.
Machine Flexibility and Versatility
A versatile vertical packing machine offers the flexibility to accommodate different packaging formats, sizes, and configurations. Consider whether the machine can accommodate changeable bag lengths, several fillers for various goods, and quick changeover capabilities to reduce downtime during product transitions. Versatility is key to adapting to evolving market demands and expanding product lines without significant investment in additional machinery.
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Packaging Seal Integrity and Quality
The seal integrity of packaged products is paramount to ensure freshness, hygiene, and product protection throughout the distribution and storage process. Evaluate the sealing mechanism of the vertical packing machine, including heat sealing, ultrasonic sealing, or impulse sealing, to determine its effectiveness in creating strong and consistent seals. Conduct seal integrity tests to verify the machine's performance under various operating conditions and environmental factors.
Ease of Operation and Maintenance
A user-friendly interface and intuitive controls enhance the operational efficiency of the vertical packing machine while reducing the likelihood of errors and downtime. Consider how accessible critical components are for cleaning, maintenance, and troubleshooting. In addition, inquire about the availability of technical support, training resources, and spare parts to ensure continuous operating reliability and avoid production disruptions.
Footprint and Space Constraints
The physical footprint of the vertical packing machine is another important consideration, especially if you have limited space in your production facility. Measure the available space and assess whether the machine can be integrated seamlessly into your existing packaging line layout. Some vertical packing machines offer compact designs or modular configurations that optimize space utilization without compromising performance.
Total Cost of Ownership (TCO) and Return on Investment (ROI)
Assessing the total cost of ownership (TCO) involves considering not only the upfront purchase price of the vertical packing machine but also ongoing operating costs, maintenance expenses, and potential productivity gains. Conduct a thorough cost-benefit analysis to determine the machine's return on investment (ROI) across its life cycle. To establish the investment's long-term economic sustainability, consider aspects such as energy efficiency, reduced material waste, labor savings, and scalability.
Conclusion
Investing in a vertical packing machine requires a thorough assessment of various factors to ensure optimal performance, reliability, and compliance with industry standards.
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Ten Tips for Buying a Vertical Form-Fill-Seal Machine
Strategies companies can use to grow business through successful packaging automation.
Buying a vertical form-fill-seal machine for the first time can be a daunting undertaking. Each manufacturer offers its own flavor of technology and even seemingly comparable machines from different manufacturers can vary widely in price. Use the following ten tips to help guide the purchasing process to a successful conclusion.
Tip 1: Align machine design to the highest volume package
Many first time buyers purchase a vertical form-fill-seal machine large enough to package all of their bags from the widest on down to the narrowest. On the surface this makes sense – buy one machine and automate the entire operation. The problem with this approach is that the wider the bag the bigger the form-fill-seal machine and the more expensive. Furthermore, the large machines tend to run the wider bags just fine, but don’t perform as well filling the narrower ones.
A more effective strategy for buying the first machine is to size the machine to the width of the highest volume bags – the size that most needs automation. That machine will be optimized for the bread and butter package size and will run the fastest, use the least material, and be the most cost effective to operate. Perhaps continue semi-automatic operations for the other sized bags or consider a second machine down the road. Refrain from designating one machine to be a jack of all trades because it will end up becoming a master of none. That vertical form-fill-seal machine simply won’t live up to expectations and will be a potential headache for years.
Tip 2: Work with an OEM that understands the application
There is both an art and a science to manufacturing a machine that will run for years without issues. Work with a manufacturer with a track record of success in similar if not identical application in terms of product and film type. That manufacturer knows what it takes to be successful in that application.
Tip 3: Be open to packaging suggestions
Some customers come to the OEM and say, we want to run this identical bag. Matrix advises customers to stay open to alternatives. A slightly different width, length, or film type may run with much better efficiency than the original on a high-speed automated machine. This doesn’t mean that the original is always discarded. It is not. Simply be open to discussing the options. Furthermore, expect the manufacturer to provide sample bags. Work with the manufacturer on any needed improvements.
Tip 4: The manufacturer should be able to recommend a number of film suppliers
Film companies are experts in films. They invest in the latest manufacturing technology to reduce cost and improve performance. The machine OEM should have experience working with the best film manufacturers and make recommendations to its customers on the ones best suited to an application. Do not buy film from the form-film-seal OEM because it is simply a revenue generator and not in the best interest of the customer.
Tip 5: The machine OEM should provide flexibility in fillers
The filler is a specialized machine that collects the project and then is synchronized to meter product into the form-fill-seal machine. Fillers are optimized for the type of product being packaged. Just like film companies being expert in what they do, filler companies are expert in the different designs for various products. During the life of one form-fill-seal machine there may be two, three, four, or more fillers attached to the machine because of changing product mixes.
The form-fill-seal manufacturer of choice will have software already installed on their machine that will synchronize various fillers. As time goes on and fillers are changed, the software on the form-fill-seal machine synchronizes to the new filler. This leads to optimum installation time and higher uptime for the machine. For example, in its standard software package Matrix has eight different control methods for synchronizing fillers. With this software strategy changing fillers is seamless. Working with outside film suppliers and having the flexibility of switching fillers ensures that the equipment purchased today will grow with the future needs of the company.
Tip 6: Tooless changeover and other key operation strategies
Being able to effectively run a number of bag sizes – similar widths and various lengths – on one machine gives the organization greater flexibility. A fast way to “changeover” the machines between different bag sizes is to have the operator switch between different size filling tubes without the need of wrenches, screw drivers, and other tools. This is called tooless changeover and it is a must for the organization because it is fast, effective, and does not require maintenance personnel to be taken away from more urgent tasks to swap a part.
A new bag size means a new roll of film needs to be strung onto the machine. The form-fill-seal OEM should demonstrate stringing a new role. If this process is time consuming and cumbersome for the OEM, it will be so for the operator as well and much time will be lost during changeover. Look for speed and simplicity.
Another thing to look at is the operator interface. The interface should be intuitive and also multilingual to accommodate a range of operators. The onscreen help functionality should actually be able to help and not require a software engineering degree to navigate.
Tip 7: Beware of 360-degree timing
For the past generation, the norm in form-fill-seal machines has been 360-degree timing. As the film is pulled down, formed, filled, and sealed, timing cams revolve one whole revolution – 360 degrees. Temperature, time, and pressure of the sealing process are all set to that one revolution. For example, a 360-degree machine may be calibrated at the factory to run 30 bags per minute – 30 360-degree revolutions per minute. When this machine is installed it is set, in this example, to run optimally at the 30 bags per minute speed. However, what happens if the customer for any number of reasons needs to speed up or slow down the production rate? All of the timing cams on the machine must be readjusted, a time consuming and frustrating task to perform and to get right.
The latest generation machines do not use 360-degree timing. Speeding up or slowing down these machines does not affect the optimum sealing time and temperature. Ask the OEM whether they are using the 360-degree timing. If the answer is yes, look for a more modern control and timing strategy.
Tip 8: The base price should include stainless steel construction, registration capability, and automatic web guide control
Some OEMs keep the base price of machines low by leaving out essential features. Without those features, the machine is no bargain. Ascertain whether the base price of the machine covers stainless steel construction, registration capability, and automatic web guide control.
Stainless steel is vital for long service life and food safety
Print registration ensures bags and copy lineup
Automatic web guide control ensures proper sealing, optimum productivity, and low waste
If the base price does not include these features, ask the OEM for the price of the machine with those features. Because along with all of the other features described in this white paper, they are required for an optimum machine experience.
Tip 9: Ask the manufacturer for the average yearly operating cost
A number of parts on the machine such as the knives, cartridge heaters, and ware strips are considered consumable because they will need to be replaced on a regular basis. Other parts like knife cylinders that operate at warm temperatures need to be replaced more frequently than other components, but not as often as consumables. On-going consumables and replacement part costs should be considered in a purchasing decision. The OEM should have this information.
Tip 10: Keep it simple
Complexity and reliability tend to be at odds. Ask the OEM for its design strategy. Do the words simple come up? Open the control cabinet. Compare the differences in appearance and number of components between suppliers. Is one clean and streamlined and the other crammed?
It is also a good idea to visit the manufacturing plant. Ask the design engineers about their basic design philosophy. Watch how common tasks on the machine like changeover are performed. If it looks hard for the manufacturer, it will not be any easier for the machine’s operator. Talk with the OEM’s customers. Ask those customers about their purchasing experience.
Every application has its uniqueness. Yet there are commonalities as well. Use these ten tips to help successfully guide the purchasing decision.
Matrix Packaging Machinery (a Pro Mach Company)
(888) 268-
Buying a vertical form-fill-seal machine for the first time can be a daunting undertaking. Each manufacturer offers its own flavor of technology and even seemingly comparable machines from different manufacturers can vary widely in price. Use the following ten tips to help guide the purchasing process to a successful conclusion.
Tip 1: Align machine design to the highest volume package
Many first time buyers purchase a vertical form-fill-seal machine large enough to package all of their bags from the widest on down to the narrowest. On the surface this makes sense – buy one machine and automate the entire operation. The problem with this approach is that the wider the bag the bigger the form-fill-seal machine and the more expensive. Furthermore, the large machines tend to run the wider bags just fine, but don’t perform as well filling the narrower ones.
A more effective strategy for buying the first machine is to size the machine to the width of the highest volume bags – the size that most needs automation. That machine will be optimized for the bread and butter package size and will run the fastest, use the least material, and be the most cost effective to operate. Perhaps continue semi-automatic operations for the other sized bags or consider a second machine down the road. Refrain from designating one machine to be a jack of all trades because it will end up becoming a master of none. That vertical form-fill-seal machine simply won’t live up to expectations and will be a potential headache for years.
Tip 2: Work with an OEM that understands the application
There is both an art and a science to manufacturing a machine that will run for years without issues. Work with a manufacturer with a track record of success in similar if not identical application in terms of product and film type. That manufacturer knows what it takes to be successful in that application.
Tip 3: Be open to packaging suggestions
Some customers come to the OEM and say, we want to run this identical bag. Matrix advises customers to stay open to alternatives. A slightly different width, length, or film type may run with much better efficiency than the original on a high-speed automated machine. This doesn’t mean that the original is always discarded. It is not. Simply be open to discussing the options. Furthermore, expect the manufacturer to provide sample bags. Work with the manufacturer on any needed improvements.
Tip 4: The manufacturer should be able to recommend a number of film suppliers
Film companies are experts in films. They invest in the latest manufacturing technology to reduce cost and improve performance. The machine OEM should have experience working with the best film manufacturers and make recommendations to its customers on the ones best suited to an application. Do not buy film from the form-film-seal OEM because it is simply a revenue generator and not in the best interest of the customer.
Tip 5: The machine OEM should provide flexibility in fillers
The filler is a specialized machine that collects the project and then is synchronized to meter product into the form-fill-seal machine. Fillers are optimized for the type of product being packaged. Just like film companies being expert in what they do, filler companies are expert in the different designs for various products. During the life of one form-fill-seal machine there may be two, three, four, or more fillers attached to the machine because of changing product mixes.
The form-fill-seal manufacturer of choice will have software already installed on their machine that will synchronize various fillers. As time goes on and fillers are changed, the software on the form-fill-seal machine synchronizes to the new filler. This leads to optimum installation time and higher uptime for the machine. For example, in its standard software package Matrix has eight different control methods for synchronizing fillers. With this software strategy changing fillers is seamless. Working with outside film suppliers and having the flexibility of switching fillers ensures that the equipment purchased today will grow with the future needs of the company.
Tip 6: Tooless changeover and other key operation strategies
Being able to effectively run a number of bag sizes – similar widths and various lengths – on one machine gives the organization greater flexibility. A fast way to “changeover” the machines between different bag sizes is to have the operator switch between different size filling tubes without the need of wrenches, screw drivers, and other tools. This is called tooless changeover and it is a must for the organization because it is fast, effective, and does not require maintenance personnel to be taken away from more urgent tasks to swap a part.
A new bag size means a new roll of film needs to be strung onto the machine. The form-fill-seal OEM should demonstrate stringing a new role. If this process is time consuming and cumbersome for the OEM, it will be so for the operator as well and much time will be lost during changeover. Look for speed and simplicity.
Another thing to look at is the operator interface. The interface should be intuitive and also multilingual to accommodate a range of operators. The onscreen help functionality should actually be able to help and not require a software engineering degree to navigate.
Tip 7: Beware of 360-degree timing
For the past generation, the norm in form-fill-seal machines has been 360-degree timing. As the film is pulled down, formed, filled, and sealed, timing cams revolve one whole revolution – 360 degrees. Temperature, time, and pressure of the sealing process are all set to that one revolution. For example, a 360-degree machine may be calibrated at the factory to run 30 bags per minute – 30 360-degree revolutions per minute. When this machine is installed it is set, in this example, to run optimally at the 30 bags per minute speed. However, what happens if the customer for any number of reasons needs to speed up or slow down the production rate? All of the timing cams on the machine must be readjusted, a time consuming and frustrating task to perform and to get right.
The latest generation machines do not use 360-degree timing. Speeding up or slowing down these machines does not affect the optimum sealing time and temperature. Ask the OEM whether they are using the 360-degree timing. If the answer is yes, look for a more modern control and timing strategy.
Tip 8: The base price should include stainless steel construction, registration capability, and automatic web guide control
Some OEMs keep the base price of machines low by leaving out essential features. Without those features, the machine is no bargain. Ascertain whether the base price of the machine covers stainless steel construction, registration capability, and automatic web guide control.
Stainless steel is vital for long service life and food safety
Print registration ensures bags and copy lineup
Automatic web guide control ensures proper sealing, optimum productivity, and low waste
If the base price does not include these features, ask the OEM for the price of the machine with those features. Because along with all of the other features described in this white paper, they are required for an optimum machine experience.
Tip 9: Ask the manufacturer for the average yearly operating cost
A number of parts on the machine such as the knives, cartridge heaters, and ware strips are considered consumable because they will need to be replaced on a regular basis. Other parts like knife cylinders that operate at warm temperatures need to be replaced more frequently than other components, but not as often as consumables. On-going consumables and replacement part costs should be considered in a purchasing decision. The OEM should have this information.
Tip 10: Keep it simple
Complexity and reliability tend to be at odds. Ask the OEM for its design strategy. Do the words simple come up? Open the control cabinet. Compare the differences in appearance and number of components between suppliers. Is one clean and streamlined and the other crammed?
It is also a good idea to visit the manufacturing plant. Ask the design engineers about their basic design philosophy. Watch how common tasks on the machine like changeover are performed. If it looks hard for the manufacturer, it will not be any easier for the machine’s operator. Talk with the OEM’s customers. Ask those customers about their purchasing experience.
Every application has its uniqueness. Yet there are commonalities as well. Use these ten tips to help successfully guide the purchasing decision.
Matrix Packaging Machinery (a Pro Mach Company)
(888) 268-
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