Like any manufacturing business, the food packaging industry is always looking for the best ways to maximize efficiency while maintaining quality standards. Selecting the right equipment is essential to achieving these goals.
There are two main types of packaging machines: horizontal form fill seal (HFFS) machines and vertical form fill seal (VFFS) machines. In this post, we cover the differences between vertical and horizontal form fill systems and how to decide which is right for your business.
Main Differences Between Vertical and Horizontal Form Fill Seal Systems
Both horizontal and vertical packing machines improve efficiency and production speed in food packaging facilities. However, they differ in the following significant ways:
Orientation of Packaging Process
As their names indicate, the main difference between the two machines is their physical orientation. HFFS machines, also known as horizontal flow wrap machines (or simply flow wrappers), wrap and seal goods horizontally. By contrast, VFFS machines, also known as vertical baggers, package items vertically.
Footprint and Layout
Due to their horizontal layout, HFFS machines have a much larger footprint than VFFS machines. While you can find machines in different sizes, horizontal flow wrappers are typically much longer than they are wide. For example, one model measures 13 feet long by 3.5 feet wide, while another measures 23 feet long by 7 feet wide.
Suitability for Products
Another key difference between HFFS and VFFS machines is the type of products they can handle. While horizontal packaging machines can wrap everything from small objects to bulky items, they are best for single solid goods. For example, food packaging companies may choose HFFS systems for bakery products and cereal bars.
Vertical baggers, on the other hand, are better suited for items of varying consistencies. If you have a powder, liquid, or granular product, a VFFS machine is the better choice. Examples in the food industry are gummy candies, coffee, sugar, flour, and rice.
Sealing Mechanisms
HFFS and VFFS machines create a package from a roll of film, fill it with the product, and seal the package. Depending on the packaging system, you may see a variety of sealing mechanisms: heat seals (using electric resistance), ultrasonic seals (using high-frequency vibrations), or induction seals (using electromagnetic resistance).
Each seal type has its pros and cons. For example, a classic heat seal is reliable and cost-efficient but requires a cooling step and a larger machine footprint. Ultrasonic mechanisms create hermetic seals even for messy products while reducing packaging material consumption and sealing times.
Speed and Efficiency
While both machines offer high efficiency and strong packing capacity, horizontal flow wrappers have a clear advantage in terms of speed. HFFS machines can pack a large number of products in a short time, making them especially useful for high-volume applications. Servo drives, sometimes called amplifiers, enable HFFS machines to maintain precise control at high speeds.
Packaging Format
Both systems allow for flexibility in packaging formats, but horizontal flow wrappers permit a greater variety of types and closures. While VFFS machines can accommodate bags of multiple sizes and styles, HFFS machines can accommodate pouches, cartons, sachets, and heavier bags with nozzles or zippers.
Operational Mechanisms and Principles
Horizontal and vertical packaging machines have numerous similarities. Both are made of stainless steel, both are suitable for the food and medical industries, and both form, fill, and seal packages in one operation. However, their physical orientation and mode of operation differ.
Explanation of How Each System Operates
HFFS systems move products along a horizontal conveyor belt. To make the pouch, the machine unwinds a roll of packaging film, seals it at the bottom, and then seals it along the sides in the correct shape. Next, it fills the pouch through the top opening.
This stage may include hot fills for heat-processed products, clean fills for non-heat-processed goods, and ultra-clean fills for cold-chain distribution. Finally, the machine seals the product with the proper closure, such as zippers, nozzles, or screw caps.
VFFS machines work by pulling a roll of film through a tube, sealing the tube at the bottom to form a bag, filling the bag with the product, and sealing the bag on the top, which forms the bottom of the next bag. Finally, the machine cuts the bottom seal in the middle to separate the bags into individual packages.
A principal difference from horizontal machines is that vertical machines rely on gravity to fill the packaging, dropping the product into the bag from above.
Which System Requires a Higher Initial Investment: Vertical or Horizontal?
Whether you choose a vertical or horizontal packing machine, costs will vary depending on each system’s size, features, capabilities, and customization. However, most industry insiders consider VFFS the most cost-effective packaging solution. But that’s only true if they work for your product. In the end, the right system for you is the one that fits your needs and optimizes your production line.
What Are the Ongoing Maintenance Costs Associated With Each System?
Beyond the initial price, all packing systems require ongoing cleaning, maintenance, and repairs. However, VFFS machines also have the edge here, as they are less complicated and need less maintenance. Unlike horizontal packaging systems, vertical baggers can only form one package type and only have one filling station.
What Packaging Automation Solution Is Right for You?
If you’re still wondering about vertical vs. horizontal form fill systems, contact the experts at soontrue today. We offer a range of HFFS and VFFS systems to meet your needs, plus expert guidance to help you choose the right one.
Post time: Dec-25-2024