The question to ask before every route planning session
Anyone planning a packaging line must first decide on the bag process: Should bags be formed and filled from a roll of film—or should ready-made bags be purchased and sealed? The Vertical Form-Fill-Seal (VFFS) machine represents the first path, the Bag-Filling Machine for Pre-Made Bags for the second one. Both approaches are well-established; the decision is based on five criteria: cycle time, material costs per bag, bag appearance, format flexibility, and format changeover.
Comparison at a Glance
| Criterion | VFFS machine | Bag Packaging Machine (Pre-assembled) |
|---|---|---|
| Clock speed | 40 to 80 beats per minute, multi-track up to 200+ | 30 to 60 bags per minute. |
| Material costs per bag | Film from a roll – lowest cost | Pre-made bags, which typically cost several times the cost of the film |
| Pouch-like appearance | Cushion shape, standard print | High-quality formats: stand-up pouches, quad-seal pouches, spout pouches, matte films |
| Shapes from a roll of film | Pillow pouches, 3-side seal, stick packs, block bottom | – (Formats are purchased) |
| Format Change | 20 to 45 minutes, mold change | 10 to 30 minutes, form parts plus bag magazine |
| Typical Applications | Rice, snacks, sugar, coffee, pet food, mass-produced goods | Premium food products, coffee, pet food, powders sold in stores, liquids with pour spouts |
Cycle Rate: Where the VFFS Machine Leads the Way
The VFFS machine Operates without grippers or a magazine—forming, dosing, and sealing are performed in a continuous process. For free-flowing products, 40 to 80 cycles per minute is standard in the industry. Multi-lane systems can achieve even higher speeds: Stick Pack Machines With 8 to 12 strands, they can produce a combined total of over 200 bags per minute.
The Pre-packaged Bag Line is limited by bag handling: Grippers must pick up, open, fill, and set down each bag individually. The industry standard is 30 to 60 bags per minute. This is too slow for mass-market goods in the food retail sector; for premium products in moderate quantities, it is sufficient.
Material costs: the biggest driver over the term
Film from a roll costs a fraction of the price of a finished bag—in this industry, the price of a finished bag is typically several times higher than the cost of the film alone for the same size. Over millions of bags, this difference adds up faster than any difference in machine price.
As a rough estimate based on disclosed assumptions: A production line operating at 50 bags per minute for 8 hours a day produces approximately 24,000 bags per day. If the finished bag (assumption) costs €0.08 and the film of the same size (assumption) costs €0.03, the daily difference amounts to approximately €1,200. These figures are examples—your actual calculation parameters will be provided by film suppliers and bag manufacturers for your specific size.
Bag Design: Where Pre-Packaged Bags Take the Lead
Pre-made bags are assembled in advance, and there are virtually no limits to the quality options available: matte films with a soft-touch finish, windows, embossed seal seams, Stand-up pouches with a sturdy base, Quad-Seal Edges or built-in Spout for liquids. Reproducing these formats using the VFFS process is only possible to a limited extent—block-bottom pouches with a folding mechanism are the exception, not the rule.
If your business partner or brand strategy calls for a high-quality shelf presence, there’s no getting around pre-made bags. If the bag is only there to protect and hold the product, you’re paying for a look that no one sees.
Format Flexibility and Format Changes
The VFFS machine changes formats via the forming shoulder, sealing jaws, and fill sizes—typically within 20 to 45 minutes, as is standard in the industry. New formats can be introduced without requiring new tools from the bag supplier; a film change is all that’s needed, as long as the film width fits within the machine’s specifications.
The pre-made bag line can be changed in 10 to 30 minutes, but requires the appropriate bags for each format to be in stock: storage space, the bag manufacturer’s minimum order quantities, and lead times are all factored into the calculation. The detailed process is described in the article Format Change on Packaging Machines.
A Five-Question Decision-Making Framework
- How many bags per minute do your sales volumes require? Over 60 and standard format → VFFS. Under 60 and premium format → Pre-made bags.
- What are the visual requirements for your sales channel? Shelf display with base and spout → Pre-made pouches. Retail products in pillow-style packaging → VFFS.
- What is the annual material cost per bag? Compare the cost of film to the price of pre-made bags based on annual volume—that’s the biggest factor.
- How many formats do you use? Few, consistent formats → Pre-made pouches can be stockpiled. Many varying formats → VFFS with film change.
- Who supplies the bags? A second supplier in the chain means lead time, minimum order quantities, and quality inspection of the bag opening.
Frequently Asked Questions
Is a VFFS machine always less expensive?
As for the material, yes—film from a roll costs less per bag. When it comes to machine cost, both concepts depend on the configuration; highly automated pre-made bag lines with checkweighers and feeding systems are significantly more expensive than simple VFFS machines.
Can a VFFS machine produce stand-up pouches?
Limited. Block-bottom pouches with a gusset and simple stand-up configurations are possible; high-quality formats with pour spouts, zippers, and quad-seal edges are the specialty of the pre-made pouch line.
What about small quantities?
For production rates of around 30 bags per minute, a fully automated line is often not cost-effective. Semi-automatic workstations for pre-made bags with manual filling are then the standard starting point.
Are there any hybrid solutions?
Yes—facilities with two product lines run both systems in parallel: VFFS for high-volume mass-market products and pre-made bags for the premium brand. The dosing modules (multihead scale, screw feeder) can be allocated to either line as needed.
Related pages: What is a vertical form-fill-seal (VFFS) machine? | What is a bagging machine for pre-made bags? | Guide to Bag Filling Machines | Coffee Packaging Machine
Request technical specifications and a quote for your production line. Please specify the product, bag size, and target output (bags/min.) – Request Technical Specifications and a Quote.
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