The vertical form, fill, and seal (VFFS) machine and the flow packer address the same problem in different ways: both use a roll of film for packaging, but the VFFS creates individual pouches, while the flow packer forms a pillow-style package around the product. Choosing the wrong machine will cost you in terms of speed, film, or product quality. This guide walks you through the criteria that determine your choice.
Differences in Operation
In a VFFS machine, film runs from a roll down over a forming shoulder. The machine forms the bag vertically, closes it at the bottom, fills it from a dosing device located above the machine, and seals it at the top. The product falls into the bag by gravity.
In a horizontal flow packer (HFFS), the product rests on a conveyor chain. The film is folded around the product, sealed along its length, and trimmed on both sides for each package. The product is carried, not dropped.
Side-by-Side Comparison
| Criterion | Vertical Form, Fill, and Seal (VFFS) Machine | Horizontal flow packer (HFFS) |
|---|---|---|
| Product Type | Bulk material, powder, liquid, paste | Solid products with their own shape |
| Packaging | Loose-packaging, from pillow pouches to doypacks | Cushion packaging around the product |
| Typical speed | 30 to 80 bags per minute | 100 to 300 packages per minute |
| Dosing device | Multihead weigher, screw feeder, or piston filler | Usually not necessary |
| Format Change | 10 to 30 minutes | 15 to 45 minutes |
| Transparency | Bagging film off the roll; mono-PE available | Cushioning film with center printing is standard |
The Six Criteria in Practice
Product shape. Fragile or dimensionally stable products—cookies, bars, chocolate—should be packaged on a flow packer; a 1.5-meter drop is enough to cause breakage. Bulk goods and liquid products should be packaged in a VFFS.
Output Goal. A flow packer typically runs at a rate of 100 to 300 packages per minute, while a VFFS runs at 30 to 80 bags per minute. If you convert this to kilograms per hour, the difference varies by product: a 5-kg bag compensates for the slower pace.
Packaging image. A loose bag stands or hangs on the shelf; pillow-style packaging encloses the product and features printed graphics. The retailer’s expectations play a major role in the choice.
Dosing weight. Only the VFFS dispenses: using a multi-head weigher for granules and snacks, a screw feeder for powder, or a piston filler for liquids and pastes. The flow packer relies on a pre-weighed or pre-counted product feed.
Plastic Film and Sustainability. Both machines operate from the roll and process recyclable single-material feedstock, provided the sealing settings have been adjusted. Compare the film consumption per 1,000 bags before you make your choice—that difference will remain throughout the product's lifespan.
Line integration. A VFFS is tall (approximately 3 to 4 meters, including the dosing unit) and takes up minimal floor space. A flow packer is long and requires a steady, even product feed.
Here's how to choose in four steps
- Line up your products: standing or lying down.
- Specify the output target in bags or packages per minute.
- Select the packaging type for each sales channel: individual bag or pouch packaging.
- Request a quote for both machine types with the same specifications for the product, output, and film.
What We've Learned from Experience
- Snack manufacturers often run both machines side by side: crispy snacks in the flow packer, family-size bags of granulated mix on the VFFS.
- Fragile products in a VFFS machine are prone to breakage; a breakage rate of just a few percent is enough to warrant reconsidering the choice of machine.
- If you request quotes for both types based on the same test specifications, you're comparing apples to apples.
When neither option works
If the stand-up pouch with a spout is the selling point, then a packaging machine for preformed bags more logical than a VFFS. For bottles and jars, a bottle filler is the right choice. For small production runs of fewer than 20 bags per minute, the investment often isn't worth it compared to manual or semi-automatic filling.
Frequently Asked Questions
Q: Is a flow packer faster than a VFFS?
Yes, for solid products: typically 100 to 300 packages per minute, compared to 30 to 80 bags per minute. For bulk goods and liquids, the VFFS remains the only one of the two that can handle the job.
Q: Can a VFFS also package solid products?
Only if the product can withstand the fall, such as heavy or sturdy items. Fragile products will break.
Q: Which machine works with recyclable film?
Both. Mono-PE film requires specific sealing temperatures and times—around 120 to 160 °C—and a seal that has been re-approved for this type of film.
Related pages
vertical form, fill, and seal machine | flow packer | multi-head weigher | packaging machine for preformed bags | Sustainable VFFS systems
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