7. Core Application Areas: Comprehensive Coverage from Food to Industry
8. Flow pack - Difference of reciprocating type and the rotary type
In order to fulfil their production volumes and, at the same time, cater to increasing expectations from end users regarding product integrity, shelf-life and presentation, businesses from a variety of industries are turning to solutions that are fit for these increasingly consumer-conscious times.
There are several available packaging technology and flow pack or Horizontal Form-Fill-Seal (HFFS) is one of the most popular and increasingly common method of packing across various industries. The considerable market size, as well as anticipated expansion, the product has on the future state of the overall package sector, further illustrates just how highly regarded this type of packaging method is among corporations and the industry as a whole.
Typically packaged in a traditional box, this type of packaging may not work for every shape of product — in contrast, flow wrap packaging easily adapts. Whatever the shape of the product, flow wrap packaging snugly wraps it, be it round product, oval, triangular, or any irregular shaped product.
Various Packaging Formats:
Flow wrap packaging can do so much more than traditional pillow-style packaging — it can produce a range of packaging formats, such as:
Stand-Up Packaging: Great for display items like snacks or little toys.
One-factor vertical continuous packaging: Applies to through consecutive class native packaging, such sausages or ice cream tablets.
Custom-Size Packaging: Ideal for products that require custom-shaped or custom-sized packaging, such as novelty cookies or industrial parts that are not compatible with standard packaging.
Customizable Packaging:
With the assistance of the relevant formers and cutting blades, flow wrap machines can be modified for customizable product shapes. This provides manufacturers the flexibility to create unique packaging formats driven by product attributes and market needs making the product more appealing for customers.
Film Transport: Two rolls of film (effective upper and lower) can be controlled by the tension control system (servo motor precision±0.1mm), the unwinding.
Product Filling: Detecting product position in real-time to ensure that the film enters in the middle.
Sealing: Side sealing is completed by constant temperature heating at 160-220°C (±1°C accuracy PID temperature control system).
Horizontal Sealing and Cutting: The rotating die works synchronously to seal and cut (ULMA two-line independent operation to reduce downtime)
Output: Cascading belts or robotic stacking system that collects and arranges the products into boxes.
A bag that is normally shaped like a pillow with a tight film wrap is called as flow-wrapped. It has longitudinal sealing (fin or overlap) and crimp seals at both ends. The film can be clear or colored. Variations include gusseted bags for bulkier items and single-serving sachets.
The stainless steel construction of flow pack machines ensures hygiene and durability. Some examples of flexible films used includes polyethylene (PE), polypropylene (PP), biaxially oriented polypropylene (BOPP), polyethylene terephthalate (PET), and laminated or metallized films. Biodegradable and compostable films are amongst other sustainable varieties being adopted as well.
Polypropylene (BOPP): Provides clarity and moisture protection.
Polyethylene (LDPE/LLDPE): High-density & Stretch Wrap for heavier items
Laminates: You can laminate for barrier properties (oxygen, UV) like PET/PE.
Environmentally-Safe Choices: PLA that can breaks down in landfill, compostable wrappers.
The choice of material depends on the needs of the product—for example, metallized films for chips, breathable micro-perforations for fresh herbs.
Flow packaging provides many benefits in multiple sectors.
It can accommodate different shapes and formats, such as pillow packs, gusseted bags, and multi-packs, making operations simplier.
Speedy efficiency is another important advantage, with machines processing up to 1500 packages per minute that reduces manual labor and increases throughput.
While MAP provides multiple enhancements, airtight seals protect products from contaminants and preservative additives, thus increasing their shelf life.
Cost-efficient construction can be achieved through minimum wastage of materials, energy-saving, and reduced labor cost. Custom films and clear packaging enhance aesthetic appeal, enhancing branding and shelf presence.
Sustainability is a growing concern in the F&B packaging world, with recyclable and biodegradable film solutions available to reduce environmental impact and carbon footprint.
Flow pack packaging boasts a diverse range of applications, spanning from food to industrial products. Here's a breakdown of its extensive use cases, along with two case studies:
Food Industry:
Snacks: Potato chips, cookies, candies, nuts, etc.
Fresh Produce: Vegetables, fruits, meat, etc.
Convenience Foods: Instant noodles, frozen foods, etc.
Pharmaceutical Industry:
Medications: Pills, capsules, powders, etc.
Medical Devices: Syringes, gauze, medical gloves, etc.
Consumer Goods Industry:
Cosmetics: Facial masks, wipes, samples, etc.
Stationery: Pens, erasers, notepads, etc.
Industrial Products:
Electronic Components: Circuit boards, chips, connectors, etc.
Hardware: Screws, nuts, small parts, etc.
Case Studies:
Food Industry Case: Cookie Packaging
Flow pack packaging effectively safeguards cookies from moisture and crushing, preserving their freshness and crispness.
The packaging material typically consists of a multi-layer composite film that provides excellent barrier properties, extending the product's shelf life.
Flow pack packaging allows for the printing of attractive designs and text, enhancing the product's appeal.
Pharmaceutical Industry Case: Medical Mask Packaging
Flow pack packaging maintains the sterility of medical masks, preventing contamination.
The packaging material usually has strong sealing properties, ensuring product safety.
Individual packaging facilitates easy carrying and use, meeting the hygienic requirements of medical products.
In conclusion, flow pack packaging has become widely adopted across various industries due to its efficiency, flexibility, and cost-effectiveness.
The common one is rotary type. The biggest difference between reciprocating and rotary type is that the structure and working operation of the end sealing part are different. The upper and lower end seals of the reciprocating type are driven back and forth by servo control, while the upper and lower end seals of the rotary type remain in the same position and rotate along the fixed roller.
The characteristic of the reciprocating type is that when the product passing through is high, the reciprocating heat sealing effect will be better than the rotary type, and the reciprocating heat sealing wrinkles are very few. Moreover, the reciprocating type is best for making corner bags with high product height, and the reciprocating type is best for tray box products
The new developments in flow wrap machine includeservo motor technology for accurate control, modular and flexible design for a variety of product sizes, high-speed wrappers for high-volume products and specialty wrappers for particular requirements. For automated product feeding, robotics are applied, and sealing technologies such as ultrasonic and box motion are enhanced for seal quality . By automating processes such as film feeding, incorporating touch screen interfaces and integrating with remote monitoring systems, smart features drive efficiency.
Upward paper film roll machines have a simpler structure, easier maintenance, and user-friendly operation with touch screen interfaces . Downward paper film roll machines are suitable for soft or bulky items, reducing material clamping, and often include features like coding and nitrogen charging . The choice depends on the product type and production needs.
Changing trends involve growing demand for sustainable packaging materials such as biodegradable and recyclable films, e-commerce impact necessitating secure packaging to protect product in transit, and a preference for convenient, single-serve packaging.
Smart packaging, such as that using QR codes, is gaining traction, as is greater automation and digital printing. Challenges facing the industry include cost pressures, environmental regulations, a need for continuous innovation, and competition from other packaging methods.
This type of packaging consists of sealing products with a continuous film, which creates a pillow pouch format, and is widely used to package individual or multi-pack units of products of a more or less uniform and shaped contour. Shrink wrap uses heat to tightly conform film around products, making it excellent for bundling and irregular shapes. Shrink wrap provides product stability and tamper evidence, while flow wrap offers versatility, visibility, and a good shelf life. Flow wrap tends to be cheaper at a higher volume, but shrink wrap can be pricier and has a less finished appearance.
Location: China
Founded: 2000
Company Type: Manufacturer
Product Range: Automated packaging solutions, specializing in flow wrapping machines and vertical form fill seal machines, with a focus on customization.
Advantages: Offers cost-effective solutions, strong customization capabilities, and a focus on efficient, automated packaging.
Location: China
Founded: 2003
Company Type: Manufacturer
Product Range: Flow wrapping machines, horizontal packaging machines, and other packaging equipment, serving various industries.
Advantages: Provides a wide range of packaging solutions, competitive pricing, and a focus on providing diverse packaging solutions.
Location: Spain
Founded: 1961
Company Type: Manufacturer
Product Range: Comprehensive range of packaging solutions, including flow wrapping, thermoforming, and vertical form fill seal machines, catering to diverse industries.
Advantages: Strong emphasis on innovation, customer service, and providing tailored packaging solutions with a high level of technical expertise.
Location: Japan
Founded: 1948
Company Type: Manufacturer
Product Range: High-speed, versatile flow wrapping machines suitable for a variety of product types, including food and industrial goods.
Advantages: Known for reliability, precision, and robust machine design, with a strong focus on advanced automation.
Location: Germany
Founded: With roots dating back to the 19th century (as part of Bosch Packaging Technology)
Company Type: Manufacturer
Product Range: Produces high-speed, precision filling machines (piston and pump fillers) suitable for cosmetic and personal care products including shampoos.
Advantages: Renowned for innovation, high quality, energy efficiency, and seamless integration with complete packaging lines.
Flow pack technology is an invaluable packaging solution when it comes to versatility, efficiency, and protective capabilities. Its constant advancements and a rising focus on sustainability with modernization will ensure its longevity across industrial sectors over the course of time, which is an inalienable need to satisfy an ever-changing market and meet demands resulting from technological advancements.
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