Buying a vertical form-fill-seal machine for the first time can be a daunting undertaking. Each manufacturer offers its own flavor of technology and even seemingly comparable machines from different manufacturers can vary widely in price. Use the following ten tips to help guide the purchasing process to a successful conclusion. 

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Tip 1: Align machine design to the highest volume package

Many first time buyers purchase a vertical form-fill-seal machine large enough to package all of their bags from the widest on down to the narrowest. On the surface this makes sense &#; buy one machine and automate the entire operation. The problem with this approach is that the wider the bag the bigger the form-fill-seal machine and the more expensive. Furthermore, the large machines tend to run the wider bags just fine, but don&#;t perform as well filling the narrower ones. 

A more effective strategy for buying the first machine is to size the machine to the width of the highest volume bags &#; the size that most needs automation. That machine will be optimized for the bread and butter package size and will run the fastest, use the least material, and be the most cost effective to operate. Perhaps continue semi-automatic operations for the other sized bags or consider a second machine down the road. Refrain from designating one machine to be a jack of all trades because it will end up becoming a master of none. That vertical form-fill-seal machine simply won&#;t live up to expectations and will be a potential headache for years. 

Tip 2: Work with an OEM that understands the application

There is both an art and a science to manufacturing a machine that will run for years without issues. Work with a manufacturer with a track record of success in similar if not identical application in terms of product and film type. That manufacturer knows what it takes to be successful in that application.

Tip 3: Be open to packaging suggestions

Some customers come to the OEM and say, we want to run this identical bag. Matrix advises customers to stay open to alternatives. A slightly different width, length, or film type may run with much better efficiency than the original on a high-speed automated machine. This doesn&#;t mean that the original is always discarded. It is not. Simply be open to discussing the options. Furthermore, expect the manufacturer to provide sample bags. Work with the manufacturer on any needed improvements. 

Tip 4: The manufacturer should be able to recommend a number of film suppliers 

Film companies are experts in films. They invest in the latest manufacturing technology to reduce cost and improve performance. The machine OEM should have experience working with the best film manufacturers and make recommendations to its customers on the ones best suited to an application. Do not buy film from the form-film-seal OEM because it is simply a revenue generator and not in the best interest of the customer. 

Tip 5: The machine OEM should provide flexibility in fillers

The filler is a specialized machine that collects the project and then is synchronized to meter product into the form-fill-seal machine. Fillers are optimized for the type of product being packaged. Just like film companies being expert in what they do, filler companies are expert in the different designs for various products. During the life of one form-fill-seal machine there may be two, three, four, or more fillers attached to the machine because of changing product mixes. 

The form-fill-seal manufacturer of choice will have software already installed on their machine that will synchronize various fillers. As time goes on and fillers are changed, the software on the form-fill-seal machine synchronizes to the new filler. This leads to optimum installation time and higher uptime for the machine. For example, in its standard software package Matrix has eight different control methods for synchronizing fillers. With this software strategy changing fillers is seamless. Working with outside film suppliers and having the flexibility of switching fillers ensures that the equipment purchased today will grow with the future needs of the company. 

Tip 6: Tooless changeover and other key operation strategies

Being able to effectively run a number of bag sizes &#; similar widths and various lengths &#; on one machine gives the organization greater flexibility. A fast way to &#;changeover&#; the machines between different bag sizes is to have the operator switch between different size filling tubes without the need of wrenches, screw drivers, and other tools. This is called tooless changeover and it is a must for the organization because it is fast, effective, and does not require maintenance personnel to be taken away from more urgent tasks to swap a part.

A new bag size means a new roll of film needs to be strung onto the machine. The form-fill-seal OEM should demonstrate stringing a new role. If this process is time consuming and cumbersome for the OEM, it will be so for the operator as well and much time will be lost during changeover. Look for speed and simplicity.

Another thing to look at is the operator interface. The interface should be intuitive and also multilingual to accommodate a range of operators. The onscreen help functionality should actually be able to help and not require a software engineering degree to navigate. 

Tip 7: Beware of 360-degree timing

For the past generation, the norm in form-fill-seal machines has been 360-degree timing. As the film is pulled down, formed, filled, and sealed, timing cams revolve one whole revolution &#; 360 degrees. Temperature, time, and pressure of the sealing process are all set to that one revolution. For example, a 360-degree machine may be calibrated at the factory to run 30 bags per minute &#; 30 360-degree revolutions per minute. When this machine is installed it is set, in this example, to run optimally at the 30 bags per minute speed. However, what happens if the customer for any number of reasons needs to speed up or slow down the production rate? All of the timing cams on the machine must be readjusted, a time consuming and frustrating task to perform and to get right. 

 The latest generation machines do not use 360-degree timing. Speeding up or slowing down these machines does not affect the optimum sealing time and temperature. Ask the OEM whether they are using the 360-degree timing. If the answer is yes, look for a more modern control and timing strategy.  

Tip 8: The base price should include stainless steel construction, registration capability, and automatic web guide control 

Some OEMs keep the base price of machines low by leaving out essential features. Without those features, the machine is no bargain. Ascertain whether the base price of the machine covers stainless steel construction, registration capability, and automatic web guide control.

Stainless steel is vital for long service life and food safety

Print registration ensures bags and copy lineup

Automatic web guide control ensures proper sealing, optimum productivity, and low waste

If the base price does not include these features, ask the OEM for the price of the machine with those features. Because along with all of the other features described in this white paper, they are required for an optimum machine experience.  

Tip 9: Ask the manufacturer for the average yearly operating cost

A number of parts on the machine such as the knives, cartridge heaters, and ware strips are considered consumable because they will need to be replaced on a regular basis. Other parts like knife cylinders that operate at warm temperatures need to be replaced more frequently than other components, but not as often as consumables. On-going consumables and replacement part costs should be considered in a purchasing decision. The OEM should have this information. 

Tip 10: Keep it simple

The company is the world’s best VFFS Vertical bagging machine supplier. We are your one-stop shop for all needs. Our staff are highly-specialized and will help you find the product you need.

Complexity and reliability tend to be at odds. Ask the OEM for its design strategy. Do the words simple come up? Open the control cabinet. Compare the differences in appearance and number of components between suppliers. Is one clean and streamlined and the other crammed?

It is also a good idea to visit the manufacturing plant. Ask the design engineers about their basic design philosophy. Watch how common tasks on the machine like changeover are performed. If it looks hard for the manufacturer, it will not be any easier for the machine&#;s operator. Talk with the OEM&#;s customers. Ask those customers about their purchasing experience.

Every application has its uniqueness. Yet there are commonalities as well. Use these ten tips to help successfully guide the purchasing decision. 

Choosing the right vertical form fill seal (VFFS) bagger

By Marc Wolf

It takes decades for a produce processor to build up its brand, but only seconds to ruin it.

A product recall traced back to contamination in your packaging equipment can destroy your credibility overnight. That&#;s why selecting the right vertical form fill seal bagger (VFFS) is critical to the success of your packaging line.

In addition to sanitary concerns, the produce industry poses a number of challenges when it comes to packaging fruits and vegetables. Thoroughly understanding your application and asking the right questions up front will help ensure you purchase the right bagger to meet your washdown and production needs. Here are five things to consider as you perform your due diligence on your next bagger.

Washdown design

The first and foremost concern for any produce processor is determining if their bagger is hygienic in design. With the safety of your customers a top priority, and how product recalls and negative news can be spread almost instantly through social media, this is an absolute must.

A hygienic design starts with the frame of the bagger. It should come with an open-frame design that allows full access for cleaning. Engineering developments in baggers like removing small nooks, crevices and fasteners that can become catch points for water, food particles and other particulates may seem small, but can in fact go a long way toward reducing breeding environments for bacteria to grow. Other features, like rounding squared edges to allow water and particulates to run off also contribute to a bagger&#;s hygienic design. 

Baggers need to be built to withstand daily washdowns with water temperatures exceeding 100° F from pressure washers spraying water over 220 PSI. The goal, of course, is to eliminate any course of contamination from the bagger.

Taking sanitization a step further, some companies are turning to professional cleaning contractors to wash their baggers and other packaging equipment. These firms specialize in disinfecting equipment, which removes responsibility from equipment operators who may not be as skilled in proactive cleaning practices.  

Mobile packaging machines

OEM manufacturers and produce processors have begun embracing the concept of mobility in packaging equipment.

The idea is rooted in bringing equipment to the harvest, rather than the other way around. When the harvest is ready in one area of the country, say California, the equipment is onsite nearby to process and package. Shortly thereafter when the harvest is ready in Arizona, the equipment is transported there to support those operations.

This is a shift in thinking from the traditional way of processing produce from a fixed location where the baggers and other packaging equipment are permanently located. Equipment may sit idle for a few months between harvests. Adding mobility to baggers, such as including casters or skids to the frame to be picked up by forklifts, can greatly save companies money by eliminating the need for a second bagger.

More SKUs

Many brands are now offering more products and SKUs as a way to appeal to a broader consumer market &#; one that increasingly is looking to better connect with their brands of choice.

While this increase in SKUs means shorter production runs, companies are packaging a larger, more diverse product offering with different bag sizes and different weights than ever before.

To accommodate this flexibility, baggers can have up to 12 changeovers in a single shift. To maintain production, changeovers need to be easy to complete in a matter of minutes and performed by the operators working that line. Effective changeovers allow operators to access the pre-loaded recipe for the next production run via the bagger&#;s touchscreen controls, and the machine does the rest. This cuts down on the engagement operators have with the bagger.

Easy operation

A well-designed bagger needs to be extremely easy to operate. That&#;s because in general, many of the employees who operate packaging equipment are entry-level, with little to no on-the-job experience operating packaging machines, and at most, have a base-level understanding of the machinery. They also may be in charge of operating several other packaging machines on neighboring lines, such as scales and conveyors, which shifts their attention to other duties. The need for easy operation is a must, and it starts with the touchscreen control panel, providing only the information the operator needs.

A larger processing facility may have packaging lines with up to 12 different touchscreens for operators to monitor. However, if some of the equipment is sourced from various suppliers, those screens will be different. The fit, form and function of a bagger&#;s touchscreen should really be designed with the operator in mind. Engineers design form fill seal machines, but it&#;s important to not design them for engineers, you need to keep the end user operator in mind.   

Performance

While a bagger&#;s advertised top-speed is a sexy stat, it really isn&#;t indicative of its true overall performance. To obtain a more accurate view of the bagger&#;s anticipated nominal speed, you need to consider how the product is processed; the volume of product per hour; how the product is fed into the bagger; and the speed of every piece of equipment behind and ahead of the bagger. 

To help ensure the bagger being built meets your production goals, a reputable supplier will want to know:

• What is the product being filled?

• What type of film will be used?

• What is the density?

• What are the flow characteristics?

• What are the bag sizes?

• What are the bag styles?

• What is the desired fill rate per minute?

• What is the target product weight?

Knowing this information upfront helps suppliers determine the scope of the project. Also, the reason to have answers to these questions in the early stages is that each one influences the other; if one of the answers to a question is unknown, it can sometimes dramatically change the scope of the project.

It&#;s important to do your homework when it comes to selecting the right vertical form fill seal for your produce processing application &#; and considering these five questions is a great place to start. Establishing communication with your supplier early on in the design process will make the project a much quicker and smoother experience for everyone involved &#; and deliver a bagger that&#;s ready for action the first day it&#;s installed.

&#; Marc Wolf is the General Manager and Vice President of Matrix (a ProMach brand), an industry-leading manufacturer of vertical form fill seal (VFFS) packaging equipment. He can be reached at [ protected]; www.matrixpm.com.

Top photo: Ease of operation is key when choosing new equipment, like a vertical form fill seal (VFFS) bagger. Photo: Matrix

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