The Evolving Flexible Packaging Landscape

Customization and Sustainability Drive Demand for Form-fill-seal Technology

By Swapna Gawale, Project Manager at Towards Packaging

Form-fill-seal (FFS) machinery offers packaging solutions that are both efficient and customizable, and produce innovative flexible packaging solutions for various sectors. The next generation of FFS technology demonstrates the transformative effects of automation on cost-effectiveness, production scalability and employee productivity, and our analysts project a 5.3% compound annual growth rate (CAGR) for FFS systems from 2023-2032.

FFS is a packaging system in which a single machine performs numerous duties during the packaging process, such as shaping the package, filling it with product, and sealing it. The FFS process for flexible packaging formats starts with a large roll of film that is formed into the shape of a bag or pouch. The film is typically  made from flexible materials like paper, metal foil, plastic film, or a mixture.

Usage of FFS machines has increased in response to demand for sustainable and straight forward packaging solutions. These machines excel at achieving operational efficiency and providing customizable packaging solutions that fit consumers changing preferences.

The global form-fill-seal market for flexible packaging is projected to grow from $8.97 billion in 2022 to $14.96 billion by 2032. Graphic courtesy of Towards Packaging.

What are the benefits of FFS technology?

FFS machines are a dependable way for companies that deal with a wide range of products — particularly those in the food packaging industry — to satisfy the demands of efficiently bagging various items. FFS technology also offers a unique benefit because it reduces human interaction during packaging, maintains hygienic conditions, and reduces the chance of contamination. Furthermore, these devices can handle a variety of materials, such as polyethylene terephthalate (PET) and polypropylene (PP), fulfilling a range of packaging specifications.

What are vertical form-fill-seal (VFFS)  machines?

VFFS machines are adaptable devices that fit into production lines smoothly, and feed product into a bag vertically. They work based on producing plastic bags from a

continuous flat roll of film. The product is inserted into the elongated plastic tube that the vertical form-fill-seal apparatus creates during the process. After that, the machine skillfully closes the package, and handles the sortation of  the leftover plastic.

They are made especially for packaging across various sectors but are most commonly used in the food packaging industry, and can be used to encase liquids and solids. These incredibly productive devices are essential to simplifying the packaging process for multiple goods.

How are horizontal form fill seals (HFFS) machines used?

HFFS machines are frequently used to package non-flowing, solid objects. With their twin sealing and moulding stations, HFFS machines offer a clear advantage to operations that need to alter pack sizes frequently. Two stations reduce downtime and increase operational efficiency by facilitating quick and easy changeovers.These modular design of FFS machinery allows flexibility in meeting various packaging specifications, leading to extensive usage in the rapidly changing food packaging sector.

The intentional implementation of VFFS and HFFS machines into assembly lines demonstrates the packaging industry’s dedication to precision and productivity.  The capacity of VFFS machines to accommodate both liquid and solid goods, in conjunction with the effective changeover capabilities of HFFS machines, renders them essential elements in the contemporary packaging environment.

What is the significance of automation in the food and beverage industry?

FFS machinery is used by multiple industries. However, the dynamic nature of the food and beverage industry has led to a growing need for effective packing automation, with manufacturers seeking to boost production capacity while improving worker safety for those involved in food processing.

In the past, food processing firms needed teams of workers to handle packaging activities because they mainly relied on manual labor to do these jobs. Automation solves the drawbacks of labor-intensive processes and significantly lowers the cost of physical labor while increasing production efficiency and improving workplace safety.

Due to the increase in demand from the food and beverage industry, cutting-edge technologies are being adopted. Using a seal packaging system is a  crucial element of this automated process, efficiently preparing products for shipment. The automation of food packaging with industrial robots is also a game-changing technology that expedites product sorting and sealing while streamlining and expediting  the entire packing process.

About the Author:

Swapna Gawale is the Project Manager at Towards Packaging. Swapna is a seasoned research consultant with expertise in conducting and analysing complex research projects across various industries. With a deep passion for knowledge discovery and a commitment to delivering actionable insights, Swapna has successfully collaborated with numerous organisations to help them make informed decisions and drive strategic growth. Download the report at: www.towardspackaging.com.