VFFS Vertical Packaging Machines: Efficiency and Challenges in Changing Bags and Products

This article explores how VFFS machines handle packaging bag and product changes, highlighting associated challenges and time requirements, helping businesses make informed equipment decisions.

Changing Packaging Bags: Quick and Easy

Changing film rolls on a VFFS machine is straightforward and typically involves:

Step-by-Step Process:

• Remove Old Roll: Operators quickly remove the nearly depleted film roll, assisted by user-friendly mechanisms.
• Install New Roll: Ensure the new film roll is correctly placed on the holder for optimal performance.
• Thread Film: Guide the new film through rollers and formers, carefully avoiding wrinkles.
• Fine-Tuning: Adjust film tension, alignment, and photocell tracking based on the new film characteristics.

Difficulty and Duration: Changing film rolls is generally simple, especially with modern automated alignment systems. Typically, it takes between 5 to 15 minutes.

Challenges in Bag Changeover:

• Correct film alignment
• Ensuring proper tension and tracking
• Selecting high-quality, compatible films

Changing Products: Complex but Crucial

Changing products on a VFFS machine involves more complexity due to differing product properties and hygiene standards.

1. Cleaning and Sanitation

Proper cleaning is essential for preventing cross-contamination, particularly in food and pharmaceutical industries. Operators may perform wet washing and disinfection, which can vary significantly in duration depending on product residue and machine design.

2. Adjusting or Replacing Weighing Devices

Adjustments or replacements might be required, such as recalibrating multihead weighers or auger fillers. Significant differences in product types could necessitate complete device changes.

3. Modifying Bag Type and Size

Adjustments to the machine’s forming components and sealing positions may be needed, especially when switching bag styles from simple pillow bags to more complex formats like stand-up pouches.

4. Setting New Parameters

Operators must reset various operational parameters, including filling speed, sealing temperature, and film tension. User-friendly interfaces help speed this process, though fine-tuning is sometimes necessary.

Difficulty and Duration: Product changeover is more challenging, requiring skilled operators and detailed knowledge. It typically ranges from 15 minutes to over an hour.

Factors Affecting Product Changeover Time:

• Product cleanliness requirements
• Complexity of bag style
• Automation levels of machinery
• Operator expertise
• Production line configuration

Summary Table

Feature	Bag Changeover (Film Roll)	Product Changeover (Formula/Material)
Main Steps	Replace film roll, thread, fine-tune	Clean, adjust weighing, modify bag, settings
Difficulty	Low	High
Time Required	5–15 minutes	15 minutes–1 hour+
Key Challenges	Film alignment, tension	Cleaning, weighing accuracy, setup complexity

Strategies to Improve Changeover Efficiency

Businesses can implement several strategies to maximize VFFS efficiency:

• Invest in Modern Equipment: Choose machines with quick-change capabilities, modular components, and automated features.
• Standardize Procedures: Clearly defined SOPs minimize errors and delays.
• Train Operators Regularly: Skilled operators significantly reduce downtime.
• Optimize Production Scheduling: Group similar production runs to minimize frequent changes.
• Preventive Maintenance: Regularly maintain machines to prevent unexpected downtime.
• Automate Cleaning: Invest in automated cleaning systems for high-hygiene products.