From Horizontal to Vertical A Look at Pillow Packer Types

Pillow packing machines are categorized into two primary types: horizontal flow wrappers and vertical form fill seal (VFFS) machines. The product's physical form—whether it is solid and stable or loose and granular—determines the best choice for an operation. Key factors like production speed, required floor space, and product handling needs also guide the selection process. The market for this equipment shows significant growth.

• The global market was valued at $6.7 billion in 2020.
• It is projected to reach $11.8 billion by 2030.
• This reflects a Compound Annual Growth Rate (CAGR) of 5.6%.

Horizontal Pillow Packers (Flow Wrappers)

Horizontal flow wrappers are engineered to package solid products that can be moved along a conveyor belt. These machines are ideal for individual items with a consistent shape and size, providing a secure and professional-looking package.

How Horizontal Packers Work

The operation of a horizontal flow wrapper follows a precise, automated sequence. The machine efficiently transforms a flat roll of film into a finished package.

1.Film Forming: The process begins as the packaging film is shaped into a continuous tube or bag around the product.

2.Sealing: The machine then creates a longitudinal seal along the bottom or top of the tube. It follows this by creating the end seals to fully enclose the product.

3.Cutting: A rotary knife cleanly cuts the film, separating each wrapped product into an individual package.

4.Product Discharge: Finally, a discharge conveyor moves the finished packages away from the machine for casing or further processing.

Key Features and Advantages

Horizontal wrappers offer significant benefits for high-volume production lines. Their primary advantage is speed, which is essential for businesses looking to scale their operations.

High-Speed Efficiency: Modern horizontal flow wrappers are built for performance. Certain models can produce up to 150 packs per minute, setting a new standard for efficiency in fresh food packaging and other industries.

This type of pillow packing machine also excels at handling delicate products. Since items travel on a conveyor and are gently enclosed by the film, the risk of breakage or damage is minimized. This makes them perfect for fragile goods like cookies and crackers.

Common Applications

The versatility of horizontal flow wrappers makes them a popular choice across numerous industries. They are particularly dominant in the food sector but also serve critical functions in non-food applications.

·Food Products:

·Cookies, wafers, and granola bars

·Chocolate tablets and candy bars

·Chewing gum sticks and pressed candy

·Fruit gum rolls

·Non-Food Products:

·Pharmaceuticals, such as blister packs

·Soaps and other personal care items

·Small hardware components

Ideal Business Use Cases

Horizontal flow wrappers represent a cost-effective and strategic investment for a wide range of operations. They are an excellent choice for businesses taking their first steps into automation or needing to manage small batch production runs. Both mom-and-pop shops and medium-sized businesses find these machines invaluable for scaling their packaging capabilities efficiently.

The versatility of flow wrappers makes them suitable for numerous sectors, particularly those producing solid, consistently shaped items. Businesses in the following industries frequently rely on this technology:

·Bakery (cookies, biscuits, and crackers)

·Confectionery (candy bars and chocolate)

·Fresh produce

·Medical devices

Flow wrappers are an efficient packaging solution for many products, especially within the Consumer Packaged Goods (CPG) category. The investment becomes highly worthwhile due to significant operational savings and value-adding features.

These machines boost productivity, lower labor costs, and enhance product safety. They also provide precise package sizing, which minimizes material waste. This technology is a cornerstone for companies packaging a diverse array of products. Common applications extend across several major categories, including:

·Food & Snacks: Baked goods, candy, and frozen foods.

·Daily Essentials: Soap bars, toothpaste, and face masks.

·Hardware & Electronics: Screws, small tools, and electronic parts.

·Medical & Healthcare: Syringes, gauze, and surgical packs.

For any business looking to improve packaging speed, consistency, and presentation for solid goods, the horizontal flow wrapper is a leading solution. It provides a clear path to increased output and a stronger market presence.

Vertical Pillow Packers (VFFS Machines)

Vertical Form Fill Seal (VFFS) machines are the ideal solution for packaging products that are loose, granular, or liquid. Unlike horizontal wrappers that move products along a conveyor, VFFS machines use gravity to fill bags from above, making them perfect for items that cannot be handled on a flat surface.

How Vertical Packers Work

The operation of a VFFS machine is a seamless vertical process. It efficiently transforms a roll of film into a filled and sealed package.

1.Film Transport and Forming: The machine pulls packaging film from a roll and guides it over a forming tube. This action shapes the flat film into a vertical bag.

2.Sealing and Filling: A vertical sealer creates the back seal of the bag. Then, horizontal sealing jaws create the bottom seal of the upper bag and the top seal of the bag below it. During this step, a connected dosing system (like a weigher or auger filler) dispenses the product down the forming tube into the bag.

3.Discharge: Once filled and sealed, a knife cuts the bag, and it drops onto a conveyor or into a receptacle for collection and case packing.

Key Features and Advantages

The most significant advantage of VFFS systems is their compact design. The vertical operation minimizes the machine's footprint, conserving valuable factory floor space. This makes them an excellent choice for facilities where space is at a premium.

Modern machines also offer advanced control and flexibility.

Advanced VFFS systems feature uniaxial or biaxial servo control, ensuring precise film pulling and positioning. This technology allows for consistent and accurate bag creation every time.

These systems can produce a wide variety of bag formats, including standard pillow bags, gusseted bags, and side-ironing bags, meeting diverse packaging needs.

Common Applications

The VFFS pillow packing machine is a workhorse in industries that handle non-solid products. Its ability to integrate with various dosing systems makes it incredibly versatile. Common applications include:

• Powder Products: Milk powder, coffee powder, spices, and detergents.
• Granular Products: Sugar, salt, rice, nuts, beans, and seeds.
• Liquid & Paste Products: Sauces, honey, shampoo, cooking oil, and jam.

Ideal Business Use Cases

Vertical Form Fill Seal machines represent a pivotal investment for businesses that handle products incompatible with horizontal conveyors. Companies packaging loose, granular, liquid, or powdered goods find these systems indispensable. The compact vertical design is particularly advantageous for facilities with limited floor space, allowing for a powerful packaging solution without extensive reorganization.

The food industry heavily relies on VFFS machines for a vast range of products. Operations packaging snacks like chips and nuts use these systems to great effect. The machines efficiently fill and seal bags, which preserves freshness and can increase production speed by up to 50%. This technology is a cornerstone for maintaining product quality and meeting high consumer demand.

VFFS machines are the go-to solution for an impressive variety of food items. Their adaptability makes them a versatile asset for many producers.

Common applications across the food sector include:

• Coffee (ground and whole bean)
• Snacks (salted snacks and bakery items)
• Cereal and Infant Formula
• Frozen Foods
• Nuts, Pasta, and Rice
• Salt, Sugar, and Spices
• Liquids (sauces, gels, and creams)

Beyond the food industry, businesses in the chemical and pharmaceutical sectors also benefit from VFFS technology. These machines provide the precision needed for packaging detergents, fertilizers, and medical powders. For any operation that requires accurate, high-speed bagging of non-solid items, a VFFS machine offers a reliable and efficient path to automation and growth.

Choosing the Right Pillow Packing Machine

Selecting the ideal packaging equipment requires a careful evaluation of several key operational factors. A business must analyze its product, production targets, and facility constraints to make an informed investment. The right choice ensures efficiency, protects product integrity, and supports long-term growth.

Product Characteristics

The physical nature of the product is the primary determinant when choosing between a horizontal and a vertical packer. Each machine type is engineered for specific product forms, and understanding this distinction is crucial for successful packaging automation.

The fundamental difference lies in how the machines handle and load items.

• Side Load (Horizontal) Case Packers: These systems excel at efficiently packing products that can be pushed or swept into cases. They work well with items that can withstand side pressure.
• Top Load (Vertical) Case Packers: These packers are designed for products that cannot be loaded from the side. They provide gentle handling for fragile items and accommodate both flexible and rigid products.

This difference in handling directly impacts which machine is suitable for a given product line. The following table breaks down how specific characteristics align with each packer type.

Production Speed and Volume

A company's production goals directly influence the selection of a pillow packing machine. Manufacturers offer equipment with varying output capabilities to match different operational scales, from small businesses to large-scale industrial plants. Evaluating current and projected volume is essential for choosing a machine that can meet demand without creating a bottleneck.

Machines are generally categorized into three performance tiers:

Businesses should select a machine with a capacity that comfortably exceeds their current production needs. This approach provides a buffer for peak demand and accommodates future growth.

Required Floor Space

The physical footprint of the machinery is a critical logistical consideration. Every production facility has unique spatial limitations, and the chosen equipment must fit within the available area while allowing for safe operation and maintenance access.

Pro Tip: Always measure the designated installation area and compare it to the machine's specifications. Remember to account for clearance on all sides for operator movement, material loading, and routine service.

Vertical Form Fill Seal (VFFS) machines are celebrated for their compact, vertical design. They occupy minimal floor space, making them an excellent choice for facilities where square footage is at a premium.

Horizontal flow wrappers, by contrast, require more linear space to accommodate their infeed and discharge conveyors. A standard horizontal machine often has a footprint with a length of over 4000mm. For example, some models measure approximately 4365mm in length by 915mm in width. While larger, this layout is necessary for smoothly handling solid, individual products along a continuous line.

Packaging Material Handling

A pillow packing machine's efficiency extends beyond its core forming, filling, and sealing functions. The way a machine handles packaging material, specifically the film, directly impacts productivity, waste levels, and overall operational costs. Modern packers incorporate sophisticated systems to automate film management, minimizing downtime and ensuring consistent package quality.

Two of the most impactful technologies are automatic film tracking and automatic splicing. These features address the two primary interruptions in the film handling process: misalignment and roll changes.

Automatic Film Tracking: This technology prevents seal integrity issues that arise when the film drifts off-center. Systems use sensors to monitor the film's edge. If the film moves, the machine automatically corrects its path. Advanced ultrasonic solutions maintain very tight tolerances, which is critical for premium packages. On some VFFS machines, the entire film carriage shifts to correct misalignment within a few cycles, preventing delays and product waste.

Automatic Film Splicing: This system eliminates the need to stop production to change an empty film roll. It creates a seamless transition from an expiring roll to a new one while the machine continues to operate at full speed.

For example, the tna Auto-splice system can complete a changeover cycle in about fifteen seconds. This incredible speed allows a single operator to manage more machines, leading to significant savings in operational costs. The system prepares the new roll while the machine is running and automatically splices the film when the old roll runs out.

Automatic splicing systems deliver a host of powerful advantages for any production line:

• They enable continuous production by joining new material rolls to old ones without stopping the machine.
• Computerized sensors detect the end of a roll and initiate a seamless changeover.
• An accumulator roller system maintains the film feed during the splice, eliminating the need to slow down.
• Operators can safely prepare new rolls without interrupting the packaging process.
• The technology significantly reduces downtime and accelerates the completion of production runs.
• It minimizes film waste through precise splice timing.

These systems often work together for optimal performance. For instance, an auto-track system can use sensors to detect the tape from a film splice. The machine can then produce an empty double bag for discharge or stop the filler before the splice, preventing wasted product. This feature is especially crucial when packaging liquids, where an unexpected splice could lead to significant spillage and cleanup. Investing in a machine with advanced material handling capabilities is a strategic decision that boosts efficiency and protects the bottom line.

Key Technical Features to Consider

Beyond the fundamental choice between horizontal and vertical machines, several technical features define a packer's performance and suitability for a specific operation. A close look at these components ensures the selected equipment will deliver the required precision, versatility, and efficiency.

Drive and Control Systems

The drive and control systems are the brain and muscle of a packing machine, dictating its precision and reliability. Modern machines often utilize servo-driven systems, which offer significant advantages over older mechanical-driven models. Servo drives provide superior control accuracy and speed, simplifying the mechanical structure. This results in smoother operation, reduced noise, and a lower failure rate, making maintenance easier for operators.

These advanced drives work in tandem with Programmable Logic Controller (PLC) systems. PLCs meticulously manage every process, from film feeding to sealing, ensuring consistent quality. They enhance user-friendliness through intuitive Human-Machine Interfaces (HMIs) where operators can easily adjust parameters like:

• Bag length
• Machine speed
• Temperature settings

This combination of servo precision and PLC intelligence guarantees high performance and simplifies daily operations.

Available Bag Formats

Modern pillow packers offer remarkable flexibility in creating different package styles to meet market demands and product requirements. The ability to produce various formats on a single machine adds significant value. Common bag types include:

• Pillow Bags: The most standard and cost-effective option.
• Gusseted Bags: Feature side folds that expand for more volume.
• Block Bottom Bags: Offer a flat base for stable, upright shelf presentation.

Beyond these basic shapes, machines can incorporate value-added features that improve the consumer experience, such as reclosable zippers and easy-open tear notches.

Measurement and Filling Systems

The filling system is critical for ensuring product quantity accuracy and integrity. The ideal system depends entirely on the product's characteristics. Machines can be integrated with various dosing equipment to handle diverse product types.

For example, auger fillers are perfect for powders like spices or flour. Multi-head weighers provide unmatched accuracy for solids like snacks and nuts. Volumetric cup fillers offer an economical solution for free-flowing items like rice or beans. Choosing the correct system is essential for minimizing product giveaway and maximizing efficiency.

GMP and CE Certifications

When selecting a pillow packing machine, certifications provide critical assurance of quality, safety, and compliance. Good Manufacturing Practice (GMP) and CE marking are two of the most important standards, indicating that a machine meets stringent industry requirements. These certifications are essential for businesses in the food, pharmaceutical, and other regulated sectors.

GMP compliance ensures that equipment is designed and operated to prevent product contamination. A machine built to GMP standards protects product integrity from start to finish. Key design and operational principles include:

• Equipment and utensils must be constructed from materials that are easy to clean and maintain.
• The machinery must not shed metal fragments, lubricants, or other contaminants during operation.
• Automated systems ensure precise filling and reliable seal integrity to protect products from spoilage.
• The machine's processes facilitate streamlined documentation, creating a clean audit trail for quality assurance.

CE marking signifies that a pillow packing machine conforms to the European Union's health, safety, and environmental protection directives. Manufacturers must conduct a thorough assessment against Essential Health and Safety Requirements (EHSRs) to earn this mark.

This process involves rigorous testing to ensure the equipment is safe under all foreseeable conditions of use. Standards like EN 415-10 simplify the certification process by providing clear guidelines for the design, manufacturing, and operation of packaging machinery. A machine with CE certification demonstrates a manufacturer's commitment to safety and opens access to European markets. Ultimately, choosing a packer with both GMP and CE certifications ensures the equipment is reliable, safe, and built for high-performance, audit-ready operations.

The two main types of pillow packers—horizontal and vertical—serve distinct product forms. Horizontal wrappers are the go-to for solid items, while VFFS machines excel with loose or liquid products. A thorough evaluation of product, speed, and space is essential for selecting the correct pillow packing machine. Choosing the right pillow packing machine optimizes efficiency and delivers a strong return on investment.

For example, one supplement maker boosted packing efficiency by 10% after switching to a more suitable system, proving the value of a proper equipment choice.

FAQ

What is the primary difference between horizontal and vertical packers?

Horizontal packers package solid items moving along a conveyor. Vertical packers use gravity to fill bags with loose, granular, or liquid products. The product's physical form is the main factor that determines the correct machine choice for an operation.

Can one machine produce different bag styles?

Yes, modern packing machines offer excellent versatility. A single machine can often create various formats, including pillow bags, gusseted bags, and even bags with special features like tear notches. This flexibility allows businesses to adapt to changing market needs.

How do servo motors improve a packing machine?

Servo motors provide superior precision and speed control. They simplify the machine's mechanical structure, which leads to smoother operation and a lower failure rate. This advanced technology ensures consistent package quality and simplifies maintenance for operators.

Why are GMP and CE certifications important?

These certifications guarantee a machine meets strict safety and quality standards. GMP ensures the design prevents product contamination. CE marking confirms compliance with EU health and safety regulations, demonstrating the equipment's reliability and operational safety for any business.