Introduction
In our previous blog, “How to Choose the Right Packaging System – The Ultimate Guide”, we walked you through the strategic framework for selecting a complete packaging production line.
This supplementary guide takes a deeper look at the technical specifications of each core component. By presenting side-by-side comparisons, material guidelines, and optimization strategies, we aim to give decision-makers a practical reference tool when evaluating and configuring their packaging line.
Whether you are considering a VFFS packaging machine, modular belt conveyor, multihead weigher, or metal detector, this guide provides the data-driven insights you need to balance performance, cost, and long-term ROI.
Packaging Machines: Comparative Overview
| Packaging Machine Type | Suitable Products | Packaging Speed | Accuracy Level | Investment Cost | Maintenance Complexity | Packaging Materials | Typical Applications |
|---|---|---|---|---|---|---|---|
| Vertical Form Fill Seal (VFFS) | Granules, powders, liquids | 20–120 bags/min | High | Medium | Medium | Composite film, aluminum foil film | Snacks, seasonings |
| Pre-made Pouch Packaging Machine | High-end products | 30–80 bags/min | Very high | High | Medium | Pre-made pouches | Nuts, pet food |
| Horizontal Form Fill Seal (HFFS) | Bars, blocks | 40–200 packs/min | High | High | Medium | PE film, composite film | Bakery, soaps |
| Multihead Weigher System | Granules, irregular pieces | 30–200 packs/min | Very high | High | Medium | Multiple | Broad food categories |
Conveyors: Technical Parameters
| Conveyor Type | Load Capacity | Speed | Hygiene Grade | Maintenance Frequency | Suitable Environment | Cost Index |
|---|---|---|---|---|---|---|
| Flat Belt Conveyor | 0.5–50 kg/m | 5–60 m/min | IP65 | Monthly | Dry/lightly damp | 100 |
| Chain Conveyor | 10–200 kg/m | 3–30 m/min | IP67 | Quarterly | Heavy load, washdown | 150 |
| Roller Conveyor | 5–100 kg/m | 10–80 m/min | IP54 | Monthly | Dry | 120 |
| Screw Conveyor | 1–20 t/h | Variable | IP67 | Monthly | Powder handling | 180 |
Metal Detectors: Performance Parameters
| Channel Size | Ferrous Detection | Non-Ferrous Detection | Stainless Steel Detection | Conveyor Speed | Typical Applications |
|---|---|---|---|---|---|
| 100×50 mm | ≥0.8 mm | ≥1.0 mm | ≥1.5 mm | ≤30 m/min | Small packs |
| 200×100 mm | ≥1.0 mm | ≥1.5 mm | ≥2.0 mm | ≤25 m/min | Medium packs |
| 400×200 mm | ≥1.5 mm | ≥2.0 mm | ≥2.5 mm | ≤20 m/min | Large packs |
| 600×300 mm | ≥2.0 mm | ≥2.5 mm | ≥3.0 mm | ≤15 m/min | Industrial |
Working Platforms: Material Selection Guide
| Industry | Recommended Material | Surface Finish | Protection Grade | Expected Lifespan | Cost Factor | Special Requirements |
|---|---|---|---|---|---|---|
| Food Processing | 304 SS | Brushed/Polished | IP65 | 15–20 yrs | 2.5 | FDA compliant |
| Pharmaceuticals | 316L SS | Electro-polished | IP67 | 20–25 yrs | 3.5 | GMP compliant |
| Chemicals | 316 SS | Acid-passivated | IP67 | 15–20 yrs | 3.0 | Corrosion resistant |
| General Industry | Q235 Carbon Steel | Powder coated | IP54 | 10–15 yrs | 1.0 | Cost effective |
System Integration & Optimization: The 1+1 > 2 Effect
Key Principles
- Standardized Interfaces – Ensure mechanical, electrical, and communication interfaces are aligned.
- Unified Control System – A centralized PLC/HMI for seamless monitoring and control.
- Data Connectivity – Enable real-time production tracking and traceability.
Performance Optimization
- Takt Time Balancing – Simulations to eliminate bottlenecks.
- Buffer Zones – Build resilience against process fluctuations.
- Preventive Maintenance – Data-driven strategies to minimize downtime.
ROI Analysis Model
Direct Benefits
- Labor savings: reduce packaging staff by 60–80%
- Reduced product giveaway: 2–5% savings
- Production efficiency: 50–200% throughput increase
Indirect Benefits
- Enhanced product consistency
- Stronger brand perception
- Improved traceability and compliance
Payback Period: 1.5–3 years (depending on scale and industry)
Conclusion
While the ultimate guide provides a roadmap for choosing your packaging system, this supplementary blog serves as a reference manual for comparing technologies, specifications, and trade-offs.
At Fill-Package, we specialize in delivering complete food packaging solutions—from belt conveyors and modular chain conveyors to multihead weighers, pouch packaging machines, checkweighers, and metal detectors.
👉 If you want to explore how these components can be tailored into a turnkey solution for your factory, contact us at www.fill-package.com.