How Do Pouch Packaging Machines Work: A Step-by-step Guide

Are you going to invest in pouch packaging machines? Have no idea of how this machine works? Then you are in the right place. 

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There are different types of pouch packaging available; each type works differently. Although they all are the same about filling and sealing parts, they can operate in other ways, vertically, horizontally, and more.

In this article, I will discuss broadly how different types of pouch packaging machines work. So, let’s get started–

Types Of Pouch Packaging Machines

In this section, I will highlight the main types in detail. Check them out-

Premade Pouch Packaging Machine

The premade pouch packaging machine does not form the pouches. Moreover, it fills ready-made pouches with specific products. The further category of premade pouch packaging machines is subdivided into rotary and horizontal premade pouch packaging machines. 

• Rotary Premade Pouch Packaging Machines: In this type of premade pouch packaging machine, the bag is moved along the circular stations using a specialized rotary method to complete filling and sealing. Usually, this layout is capable of making almost 50 pouches per minute. 

• Horizontal Premade Pouch Packing Machines: The horizontal premade pouch packing machine uses preformed pouches to fill products in a horizontal direction. Different sorts of products, such as snacks, nuts, flour, and coffee beans, are packaged with this machine as it is excellent for filling powder and granulated products. It uses an automatic pick-and-place mechanism for packaging. More often, premade stand-up pouches, flat bottom pouches, quad seal pouches, and spout pouches are suitable for this packaging machine.

Form Fill Seal Machines

In contrast to pre-made pouch packaging machines, this type of packaging can create pouches by using different kinds of materials and then proceed to further tasks. Primarily, form-fill-seal machines are of two types based on their mechanism of packaging. These are-

• VFFS Machines: Vertical form-fill-seal machine makes and fills pouches within a vertical structure. You can use it for a vast range of applications, including solid and liquid product packaging. There are two types of VFFS machines: pneumatic and servo-driven. The pneumatic machines complete filling and sealing using compressed air and are perfect for small-scale businesses. On the contrary, servo-driven machines use electric motors for the whole process. 

• HFFS Machines: Horizontal form fill seal machines form pouches first. Then, it fills and seals those pouches in a horizontal direction. It is preferable for liquid, gel and paste product packaging to limit the risk of leakage. Due to the lower cost of the premade pouch packaging machine, HFFS Machines are popular among manufacturers. 

Common Parts Of Pouch Packaging Machines

The intricate layouts of pouch packaging machines consist of some basic units. For instance, filling, sealing, transportation, and control units make a complete pouch packaging machine. Let me explain each unit in detail below.

• Filling System: The primary mechanism of a pouch packaging machine is to fill pouches with specific products, which is carried out by this filling unit. The rate of pouch packaging mainly depends on the filling system. Various types of fillers, including auger fillers, gravity fillers, and piston fillers, are used for different purposes. 
• Sealing System: The sealing unit of the pouch packaging machine tightly closes the packages to maintain the quality of the products. It is an essential step before transporting the pouches. Some standard sealing methods are ultrasonic, vacuum, induction, and many more sealing.  
• Film Transportation: This unit is responsible for moving the pouches smoothly throughout the whole process. This film transportation system monitors the film’s alignment. 
• Control Systems: The control or monitoring unit is an integral part of packaging products because it supervises the complete process. The control system ensures proper filling and sealing and maximum efficiency in manufacturing multiple batches of pouches.

How Do Pouch Packaging Machines Work?

Now, let’s discuss the complete production process of these machines. 

How Do Premade Pouch Packaging Machines Work?

Below, I mention the step-by-step process of how the premade pouch packaging machines work–

Bag Loading

In the very first step, you will see that premade pouches are loaded onto the machine, specifically inside the magazine or the hopper. In some machines, a manual pouch loading option is available, and in other machines, an automatic loading option is available.  Then, the pouches are carried towards the conveyor by the bag feeding roller. 

Printing 

The machine’s printer will engrave important information on the pouches using the thermal or inkjet printing method. 

Pouch Opening 

There is a set of jaws or mechanical grippers in the machine that opens the pouch after gripping it. In the next step, an air blower flows air inside the pouch to inflate it. Sometimes, vacuum suction is also used for this step. Thus, the pouch becomes wide open and instantly ready for further packaging. 

Packaging Product

Now, it is time to fill the pouch with an accurate dose of the product. When the pouches reach the filling station, fillers inject products into the pouch. For example, you can use volumetric filler for solid or viscous products, while auger filler is best for powder products. Also, for your liquid product, use a liquid pump.

Pouch Sealing

Here, pouches are sealed using heat, pressure or ultrasound to keep the product secure inside the pouch. The sealing jaws carry out this process on two overlapping sides of the pouch. Extra features like zipper closure or tearing edges are added in this step.

Discharge

Filled and sealed pouches are then cut away and discharged into a collection center like a belt conveyor. This conveyor transports the pouches to further checking or packing centers. 

How Do Form Fill Seal Machines Work?

If you want to perform from making pouches to sealing them at once with a single machine, the Form, Fill, and Seal (FFS) machine is the appropriate choice for you. Let’s see how it works in the next section.

Product Feeding 

First, place the products you want to pack inside pouches on the conveyor or belt of the machine. The machine will then use sensors or mechanical systems to properly position the product.

Film Feeding

In this step, the machine will form pouches for filling products. So, place a roll of film of your choice on the unwinding roller. For instance, use plastic film, laminated film, or aluminum foil, depending on your packaging needs. Then, the tensioner, along with the servo motor, will pull the movie inside the machine. 

Package Forming

Films are then moved to a pouch-forming station. Here, the sealing jaws seal the corners and form a pouch for filling materials. 

Product Filling 

In the filler station, formed pouches are packed with desired amounts of products. The Vertical Form Fill Seal machine is done longitudinally, and the Horizontal Form Fill Seal machine fills pouches horizontally. 

Pouch Sealing

After that, filled pouches are sealed with heat and adhesives. In this step, airtight and sealed pouches are made for distribution. 

Cooling

When you are done with the main steps of packaging, cool down your pouches to extend their shelf life. Using the air-blowing device to cool the pouches to complete this step. 

Cutting And Discharge

The final step of pouch packaging involves cutting and discharging. After cutting each pouch, it is collected in a detection device and case machine for end-of-line packaging. 

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Conclusion 

Although different pouch packaging works in different ways,  their filling and sealing are common parts of all the machines. So, you can easily use pouch packaging machinery for food, pharmaceutical, and chemical businesses. 

Therefore, if you want the best pouch packaging machine for your business, contact HonorPack. We offer different types of machines; choose one based on your preferences. 

FAQs

Do pouch packaging machines contribute to sustainability? 

Pouch packaging machines can contribute to sustainability by minimizing emissions and promoting recyclable materials. These machines enhance efficiency through precise cutting and forming, which lowers resource consumption. Minimum waste throughout the whole production process leads to sustainable practices.

How fast do the pouch packaging machines work?

Depending on factors like pouch size, shape, type of product, and machine speed, the ratio of pouch production varies. For example, pouch packaging machines can make approximately 30-150 pouches each minute. On the other hand, if you use high-speed machines, you will be able to produce around 400 pouches per minute. 

Can small-scale food manufacturers use pouch packaging machines?

Yes, both small and large-scale food manufacturers can use pouch packaging machines. As these machines are customizable for every business, small start-ups can use compact pouch packaging machines according to their budget needs. 

What is ultrasound sealing in a pouch packaging machine?

Some pouch packaging machines use advanced ultrasonic sealing methods to seal pouches. In this method, ultrasonic waves produce heat for sealing purposes and maintain higher product freshness. 

In today’s ever-evolving world, one packaging solution stands out as both innovative and sustainable – flexible pouches. These versatile packages have gained popularity in recent years, and in this blog post, we will explore what they are made of, their various types, and why they are such an excellent choice for a wide range of products.

The Popularity of Flexible Packaging

Flexible packaging, in the form of pouches, has risen to prominence due to the growing global emphasis on sustainability. These pouches are renowned for their minimal environmental impact, making them a preferred choice for eco-conscious manufacturers and consumers.

Flexible pouches offer sustainability advantages due to their reduced material usage compared to traditional packaging options. Constructed using fewer resources, the process helps to conserve raw materials and reduce carbon emissions. Furthermore, their lightweight design minimizes the carbon footprint during distribution.

These claims are backed by the Flexible Packaging Association (FPA), which provides this list of facts from their latest findings:

• Producing a flexible food service pouch requires 75% less energy and generates just 1/10 of CO2 emissions during production than a metal can for the equivalent amount of product.
• 1.5 pounds of flexible packaging will package the same amount of beverage or liquid foods as 50 pounds of glass.
• To transport packaging for an equal amount of product, it takes more than 26 truckloads of empty glass jars versus one truckload of empty flexible pouches.

Additionally, flexible pouches are highly adaptable, making them suitable for various product types. Their ergonomic design not only reduces packaging waste but also enhances the consumer’s experience by being easy to open, store, and reseal, thus extending the product’s shelf life. These factors combine to make flexible pouches an attractive choice for brands looking to cater to environmentally conscious consumers without compromising functionality.

Layers in Flexible Packaging Pouches

Flexible pouches are more than just a single layer of material; they are a composite of carefully selected layers that work harmoniously to protect and present your products effectively. Let’s take a closer look at these layers to understand their roles:

• Sealant Layer: The innermost layer safeguards against leakage and assists in setup of functional package aspects like fitments and closure applications.
• Barrier Layer: The barrier layer is crucial for protecting the product, preventing tears, and preserving shelf life. Materials like aluminum foil and other metalized films provide excellent barrier properties, blocking out light or inhibiting oxygen, moisture, and odor from entering or exiting the package.
• Print Layer: The print layer is where the pouch gets its vibrant graphics and branding. High-quality printing enhances the visual appeal of the package and communicates essential information to consumers, such as product details and instructions.
• Structural Layer: Structure layers offer fortitude and puncture protection for your pouch.
• Finish Layer: The finish layer serves both aesthetic and functional purposes. A matte, glossy, or soft-touch finish enhances the tactile and visual appeal of the pouch while also protecting the design of the print layer.
• Adhesive: Adhesive can be used to combine layers in a multi-material flexible package. Several lamination methods can be used, such as solventless, solvent based, or water based, depending on the unique needs of the package.

Image Source: Nobelus University

Materials Used in Flexible Pouch Films

The choice of materials for the various layers of flexible pouches depends on the specific requirements of the product and the desired outcome. Here are some common materials used in flexible pouch films and their benefits:

• PET (Polyethylene Terephthalate): PET is often used or incorporated into the barrier layer of flexible packaging. Polyester is useful for transparent packaging solutions (like view windows) and metalized films.
• Aluminum Foil: Aluminum foil is an exceptional choice for the barrier layer. It offers high resistance to moisture and oxygen entering the package and ensures the product’s freshness and longevity by retaining odors and flavors.
• PE (Polyethylene): PE is a good option for the sealant layer and can also be used in the barrier layer when combined with other films.
• BOPP (Biaxially-Oriented Polypropylene): BOPP films are unique in that they provide a moisture barrier and serve as an excellent printable film for high quality graphics with great clarity.
• Paper: For a more natural and eco-friendly look, some flexible pouches are made with paper. Paper can provide rustic charm, protection, and recyclability.

Sustainable Options: To meet the growing demand for eco-friendly packaging, sustainable materials like recyclable plastics, bio-based films, and compostable materials are increasingly being incorporated into flexible pouch designs. These options reduce the environmental footprint of the packaging while maintaining performance and functionality.

Common Types of Pouches and Their Benefits

Flexible pouches come in various designs to cater to different products and consumer preferences. Here are some common types and their associated benefits:

• Stand-Up Pouches: These pouches have a design that allows them to stand upright on store shelves. They are excellent for products like snacks, coffee, and pet food, offering convenience and visibility. You can choose from a variety of stand-up styles with different bases from gusseted to flat bottom.
• Lay Flat Pouches: Lay flat pouches are versatile and ideal for products that need to lie flat, such as frozen food and spices, and for products in personal care, pharmaceutical, and home and garden markets. The lay flat design is easy to store and stack.

Besides the layers and pouch types, several other elements can be incorporated into flexible pouches to enhance functionality and convenience. These include:

• Closure Types: In addition to zippers, pouches can feature options like sliders, press-to-close seals, or even resealable tape for easy access and resealing.
• Degassing Valve: Used for coffee and other products that emit gas, a degassing valve allows gases to escape without compromising the pouch’s integrity, ensuring freshness. It allows carbon dioxide to escape but doesn’t allow oxygen in.
• Side Seals: Side seal pouches often take up less space, making them optimized for transportation, storage, and point-of-purchase or aisle displays with hang hole. Three-sided sealed pouches are cost-effective and great for grab-and-go consumer products.
• Zipper Pouches: Pouches equipped with resealable zippers are perfect for products that consumers want to use gradually, like snacks and pet treats. The zipper ensures freshness is maintained after each use.
• Spouted Pouches: These pouches come with a spout for controlled pouring, making them ideal for liquids such as sauces, beverages, and baby food. The spout design minimizes mess and waste.
• Add-Ons: Pouches can be customized with features such as handles, tear-notches, custom shapes, child resistant features, and transparent windows to showcase the product inside.

An assortment of pouches can be ordered from MJS Packaging that fit your unique needs, including preformed, rollstock or custom. Preformed pouches will save you time, as they are already shaped and formed, ready for you to fill and close. Rollstock consists of a roll of unformed pouches. Forming, filling, and sealing the rollstock pouches on your own can allow for cost savings if you already have your own in-house machinery.

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Flexible pouches have become a staple in the world of packaging due to their sustainability advantages and versatility. As consumer preferences shift toward more eco-friendly choices, flexible pouches will continue to stand out as a leading choice.

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