A vertical form-fill-seal (VFFS) machine is an automated packaging machine that forms bags from a roll of flexible packaging film, fills them with product, and seals them. The three basic functions happen in sequence: the machine forms the package, fills it, and seals it. VFFS machines are commonly used for products such as food, powders, granules, snacks, coffee, and other products that can be packaged in flexible bags.
Unlike a pre-made pouch machine, a VFFS system starts with a continuous roll of packaging film. This allows the machine to produce and fill individual bags as part of one continuous process.
How Does a VFFS Machine Work?
The exact configuration varies by product and package, but the basic process follows several steps.
1. Film Forms the Bag
A roll of flexible packaging film is fed into the machine.
The film travels around a forming collar, which folds it into a tube. The machine then creates the appropriate seals to turn the film into an individual package.
The film can be printed or unprinted depending on the application.
2. The Product Is Measured
The product is then measured and delivered into the newly formed package.
The filling equipment depends heavily on the product being packaged. For example:
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- Weighing systems can be used for many solid products.
- Auger fillers can be used for powders.
- Volumetric systems can measure certain free-flowing products.
- Other dosing systems may be appropriate for different product characteristics.
The filling system is therefore an important part of specifying a VFFS machine.
3. The Package Is Sealed
After the product enters the bag, the machine creates the necessary seals.
Depending on the package design, this can include a top seal and bottom seal. The completed package is then separated from the film and discharged from the machine.
Some systems can also incorporate features such as tear notches, zipper closures, gas flushing, or other package components when the application requires them.
What Products Can a VFFS Machine Package?
VFFS equipment can handle a wide range of products, but the machine configuration needs to match the product’s physical characteristics.
Common applications include:
- Coffee and other dry foods
- Snacks and confectionery
- Rice, grains, and other granular products
- Powdered products
- Pet food
- Agricultural products
- Some non-food industrial products
Product characteristics such as particle size, flowability, density, moisture, and fragility can affect the choice of filling system.
🔧 Note from the Engineer: The bag-making portion of a VFFS machine is only one part of the system. The filling method can be just as important. A machine designed to package a free-flowing granular product may require a very different filling system from one packaging a fine powder. Start with the product and target package weight before choosing the machine configuration.
What Types of Bags Can a VFFS Machine Make?
VFFS machines can produce several different bag styles.
The available formats depend on the machine and film construction, but common configurations include:
- Pillow bags
- Gusseted bags
- Block-bottom or related specialty formats
- Bags with resealable features
- Bags with tear notches or other opening features
The desired bag style should be established before selecting equipment because it affects the forming, sealing, and film-handling components.
What Affects VFFS Machine Speed?
A VFFS machine’s advertised speed does not necessarily represent the production rate you will achieve with every product.
Actual output can be affected by:
- Bag dimensions
- Target fill weight
- Product flow characteristics
- Filling accuracy requirements
- Film characteristics
- Seal requirements
- Bag style
- Product settling or handling time
- Upstream and downstream equipment
For example, a machine may be capable of producing a high number of small bags per minute but operate at a lower rate when producing larger bags with heavier or more difficult-to-handle products.
What Equipment Works With a VFFS Machine?
A VFFS machine is often one part of a larger packaging line.
Depending on the application, the system may include:
- Product feeding equipment
- Multihead weighers or other filling systems
- Auger fillers
- Nitrogen flushing or gas injection
- Date or lot-code printers
- Checkweighers
- Metal detectors or other inspection equipment
- Conveyors
- Case packing equipment
The equipment upstream and downstream needs to keep pace with the VFFS machine. Otherwise, the packaging machine can become either starved for product or blocked by finished packages.
🔧 Note from the Engineer: When evaluating a VFFS system, look at the entire flow rather than the machine in isolation. A fast bagger does not increase overall production if the product feeder cannot supply it consistently or the finished bags have nowhere to go. The practical line speed is determined by the constraint in the complete process.
When Do You Need a VFFS Machine?
A VFFS machine makes sense when you need to produce flexible bags from rollstock rather than manually filling pre-made bags.
It becomes particularly useful when production volume makes manual bag forming, filling, and sealing too slow or inconsistent.
The right level of automation depends on your production volume, product, package size, bag format, labor requirements, and desired growth.
The Bottom Line
A vertical form-fill-seal machine forms bags from a roll of flexible film, fills those bags with product, and seals them in an automated process.
The machine itself is only part of the equation. The product, filling method, film, bag format, sealing requirements the product being packaged, target fill weight, bag dimensions, desired package style, production volume, and required speed. Those details provide the foundation for determining what type, and surrounding equipment all affect how well the system performs.
Before selecting a VFFS machine, define the product being packaged, target fill weight, bag dimensions, desired package style, production volume, and required speed. Those details provide the foundation for determining what type of VFFS configuration is appropriate.
Information provided by Adeneli Packaging
Eugene, Oregon | adenelipackaging.com
