On a vertical form-fill-seal machine, film is often the largest cost item over the line\u2019s 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.<\/p>\n
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\u2019re just guessing.<\/p>\n
Every millimeter of bag length counts twice\u2014on both the front and back. Example: A 150-mm-wide bag that can be made 10 mm shorter saves 0.0015 m\u00b2 of film per bag. At an average of 40 bags per minute, 8 hours a day, and 220 operating days\u2014well over 4 million bags per year\u2014that amounts to a savings of approximately 6,300 m\u00b2 of film per year.<\/p>\n
Also check the sealing edge: with a narrow, well-conditioned seam of 8 mm or less, you\u2019ll use less film than with wide, standard seams.<\/p>\n
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\u2019t end up costing you extra film.<\/p>\n
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<\/a> With a recipe memory, you can reduce setup time and, consequently, waste; train operators to follow a standardized changeover procedure.<\/p>\n 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<\/a> show.<\/p>\n 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.<\/p>\n Q: How much film does mono-PE save?<\/strong><\/p>\n 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\u2019s future-proof nature.<\/p>\n Q: What is a healthy waste percentage?<\/strong><\/p>\n Many factories aim for a roll consumption rate of less than 5%. If you measure this monthly by production line, you\u2019ll spot any deviations early on.<\/p>\n Q: Does a new machine immediately result in film savings?<\/strong><\/p>\n 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.<\/p>\n sustainable packaging solutions<\/a> | Sustainable VFFS systems<\/a> | vertical form, fill, and seal machine<\/a> | VFFS for granules<\/a><\/p>\nMeasure 4: Single-material products wherever possible<\/h2>\n
Measure 5: Reduce thickness only within the barrier requirements<\/h2>\n
Overview<\/h2>\n
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\n \nMeasure<\/th>\n Typical effect<\/th>\n Where to Find It<\/th>\n<\/tr>\n<\/thead>\n \n Pocket length 10 mm shorter<\/td>\n 0.0015 m\u00b2 per bag<\/td>\n Recipe and mold settings<\/td>\n<\/tr>\n \n Seal edge 8 mm or less<\/td>\n Less plastic wrap per bag<\/td>\n Seal Wiper and Seal Profile<\/td>\n<\/tr>\n \n Recipe-Driven Format Change<\/td>\n 20 to 50 fewer bags of trash per shift<\/td>\n Machine Operation<\/td>\n<\/tr>\n \n Mono-PE single-material<\/td>\n Recyclable waste stream<\/td>\n Film Specifications<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n<\/figure>\n Frequently Asked Questions<\/h2>\n
Related pages<\/h2>\n
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