On a vertical form-fill-seal machine, film is often the largest cost item over the line’s service life. You can control film consumption through the recipe, film procurement, and strict adherence to procedures during format changes. These five measures are the most effective.
First, measure: square meters per 1,000 bags
Determine the film consumption in square meters or kilograms per 1,000 bags. The difference between the theoretical bag surface area and the actual roll consumption is your waste percentage. Without that measurement, you’re just guessing.
Measure 1: Tighten the bag length and seal edges
Every millimeter of bag length counts twice—on both the front and back. Example: A 150-mm-wide bag that can be made 10 mm shorter saves 0.0015 m² of film per bag. At an average of 40 bags per minute, 8 hours a day, and 220 operating days—well over 4 million bags per year—that amounts to a savings of approximately 6,300 m² of film per year.
Also check the sealing edge: with a narrow, well-conditioned seam of 8 mm or less, you’ll use less film than with wide, standard seams.
Measure 2: Order custom-width film
Standard widths result in waste on both sides of the forming die. Order the roll in the exact processing width in mm and specify that width in the recipe, so that switching suppliers won’t end up costing you extra film.
Measure 3: Format change with less waste
The first 20 to 50 bags after each change are waste. With three changes per day, that adds up to 150 bags of product plus plastic wrap that you throw away. Servo-controlled machines With a recipe memory, you can reduce setup time and, consequently, waste; train operators to follow a standardized changeover procedure.
Measure 4: Single-material products wherever possible
Mono-PE is recyclable as a single material and runs on a VFFS machine with adjusted sealing settings. Sometimes a slightly greater thickness is required to achieve the same barrier performance; in that case, however, the waste stream is more valuable. European packaging regulations are moving toward recyclable packaging, as are the Sustainable VFFS systems show.
Measure 5: Reduce thickness only within the barrier requirements
A thinner film saves money per square meter, but product shelf life takes priority. Ensure that the oxygen and moisture barriers are verified before reducing the thickness, and validate the shelf life after the change.
Overview
| Measure | Typical effect | Where to Find It |
|---|---|---|
| Pocket length 10 mm shorter | 0.0015 m² per bag | Recipe and mold settings |
| Seal edge 8 mm or less | Less plastic wrap per bag | Seal Wiper and Seal Profile |
| Recipe-Driven Format Change | 20 to 50 fewer bags of trash per shift | Machine Operation |
| Mono-PE single-material | Recyclable waste stream | Film Specifications |
Frequently Asked Questions
Q: How much film does mono-PE save?
There is no fixed percentage: sometimes the film needs to be slightly thicker to achieve the same barrier performance. The benefit lies in the value of the recyclable waste stream and the material’s future-proof nature.
Q: What is a healthy waste percentage?
Many factories aim for a roll consumption rate of less than 5%. If you measure this monthly by production line, you’ll spot any deviations early on.
Q: Does a new machine immediately result in film savings?
Only if the seal edges, recipes, and changeover procedure are adjusted accordingly. The machine alone is not the solution; the film management process surrounding it determines the result.
Related pages
sustainable packaging solutions | Sustainable VFFS systems | vertical form, fill, and seal machine | VFFS for granules
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