{"id":78059,"date":"2026-09-19T10:35:57","date_gmt":"2026-09-19T02:35:57","guid":{"rendered":"https:\/\/lintyco.de\/vffs-ratgeber\/"},"modified":"2026-09-19T10:35:57","modified_gmt":"2026-09-19T02:35:57","slug":"vffs-ratgeber","status":"publish","type":"post","link":"https:\/\/lintyco.de\/en\/vffs-ratgeber\/","title":{"rendered":"VFFS Guide: The Complete Guide to Vertical Form-Fill-Seal Machines"},"content":{"rendered":"

Why This Guide?<\/h2>\n

The vertical form-fill-seal (VFFS) machine is the most widely manufactured packaging machine in the world. It packages salt and seeds, coffee and chips, screws and fertilizer. This guide summarizes what operators need to know before investing and before starting operations: design, dosing methods, a five-step selection process, film specifications, cost factors, and common beginner mistakes. The article covers the basics of how the machine works What is a vertical form-fill-seal (VFFS) machine?<\/a> \u2013 It's all about depth.<\/p>\n

The Structure: Seven Functional Groups<\/h2>\n

One Vertical filling and capping machine<\/a> consists of seven groups, each of which is configured individually:<\/p>\n

    \n
  1. Film Unwinding:<\/strong> One or two roll holders with a correction drive for the film center; for simple films, a \"T\u00e4nzler\" control loop is sufficient.<\/li>\n
  2. Mold shoulder:<\/strong> The heart of the machine. It rolls the flat film into a tube. Each bag width requires its own forming shoulder\u2014the most important component of the machine.<\/li>\n
  3. Longitudinal Sealing Unit:<\/strong> It seals the follow-up tube lengthwise, either thermally using conveyor-fed sealing tapes or by impulse sealing. Conveyor-fed tapes protect the seam and enable higher cycle rates.<\/li>\n
  4. Sealing Jaws:<\/strong> They cross the tube and create two seams in a single cycle\u2014the cross seam of the finished bag and the bottom seam of the next one.<\/li>\n
  5. Filling chute and dosing system:<\/strong> The dosing system is located above or inside the filling hopper: multihead weighers for bulk materials, screw feeders for powders, and piston feeders for liquids and pastes.<\/li>\n
  6. Cutting knife:<\/strong> It separates the finished bag from the tube\u2014either with a blade or a tear-off edge; for delicate seams, it transfers the bag to the conveyor belt using a suction cup.<\/li>\n
  7. Controls:<\/strong> HMI with recipe management. As is standard in the industry, controllers store 50 to 100 recipes\u2014sealing temperature, film length, and target weight\u2014which can be retrieved as a block.<\/li>\n<\/ol>\n

    The Right Dosing Method for Each Product<\/h2>\n

    The dosage determines accuracy and cycle rate\u2014not the bagging machine itself:<\/p>\n\n\n\n\n\n\n\n\n\n
    Product Type<\/strong><\/th>\nDosing System<\/strong><\/th>\nTypical Accuracy<\/strong><\/th>\nFrequency range<\/strong><\/th>\n<\/tr>\n<\/thead>\n
    Granules, coffee beans, snacks<\/td>\nMulti-head scale<\/td>\n\u00b10.5 to \u00b11 g<\/td>\n30 to 80 beats per minute.<\/td>\n<\/tr>\n
    Powders (flour, powdered milk, spices)<\/td>\nVolumetric Screw Feeder<\/td>\n\u00b10.5 to \u00b11 %<\/td>\n30 to 60 bags per minute.<\/td>\n<\/tr>\n
    Powder with a variable bulk density<\/td>\ngravimetric net dosing<\/td>\n\u00b10.3 to \u00b10.5 %<\/td>\n20 to 50 bags per minute.<\/td>\n<\/tr>\n
    Liquids and Pastes<\/td>\nPiston or Pipe Conveying System<\/td>\n\u00b10.5 to \u00b11 %<\/td>\n20 to 40 bags per minute.<\/td>\n<\/tr>\n
    Loose goods (cookies, bars)<\/td>\nFeeding line with product detection<\/td>\nper item<\/td>\n40 to 100 packages per minute.<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n

    Details for each product category are covered in separate articles: Granules<\/a>, Powder with a screw feeder<\/a> and Coffee Beans with Flavor Protection<\/a>.<\/p>\n

    Selection in Five Steps<\/h2>\n

    Step 1: Product Analysis<\/h3>\n

    It all starts with the product: particle size, bulk density, flow characteristics, moisture content, fat content, and susceptibility to breakage. These six parameters determine the dosing system, the hopper cross-section, and the material requirements\u2014SS304 stainless steel for product contact, and SS316 for corrosive products.<\/p>\n

    Step 2: Select a formatting program<\/h3>\n

    Bag widths and lengths define the format part set. Using a few widths with multiple lengths saves on format parts and changeover time\u2014consolidating five formats into two widths cuts the number of format parts needed in half compared to five individual formats.<\/p>\n

    Step 3: Clear the film<\/h3>\n

    The film is part of the machine\u2019s logic: composite films with an inner PE layer seal at 120 to 180 \u00b0C; thicker laminates require more sealing time and reduce the cycle rate. If you wait until after the machine is installed to select the film, you risk having a line that can\u2019t keep up with its target speed.<\/p>\n

    Step 4: Set a realistic performance target<\/h3>\n

    80 cycles per minute apply to free-flowing material, medium-sized formats, and a well-broken film. When accounting for product changes, film warping, and fluctuations in bulk density, experienced operators plan for a continuous power output of 70 to 80 % of the rated power.<\/p>\n

    Step 5: Environment and Expansion<\/h3>\n

    Conveyor systems upstream of the machine, recommendations for a weighing control system or metal detector downstream of the machine, inquiries about retrofit options\u2014the answers to these questions will determine whether the line can grow along with the business.<\/p>\n

    Film Science: Sealing Is Chemistry<\/h2>\n

    The seal is formed when the PE inner layer of the film melts and bonds under pressure. Three parameters control this: temperature, time, and pressure\u2014they\u2019re specified in every recipe. Typical defects include: a seam that\u2019s too hot becomes brittle, a seam that\u2019s too cold opens under load, and particles in the seam (dust, grease, product debris) weaken any seam. For dusty products, a filling chute extraction system should therefore be included on the list of options; for greasy products, temperature-controlled clamps with \u00b15 \u00b0C accuracy are required.<\/p>\n

    Two types of film dominate the industry: single-material structures for recyclable packaging and traditional laminates with aluminum or EVOH as a barrier. The barrier determines shelf life: coffee and snacks require protection from oxygen, while hygroscopic products require protection from moisture; both of these requirements are reflected in the choice of film and the price per bag.<\/p>\n

    Operations: Format changeovers, cleaning, replacement parts<\/h2>\n

    The Format Change<\/a> On a VFFS machine, this typically takes 20 to 45 minutes\u2014the forming shoulders, sealing jaws, and filling chute are replaced. Tool-less quick-release fasteners cut this time in half and should be a mandatory item on the procurement list when frequent changes are required.<\/p>\n

    Cleaning: Food processing facilities should schedule daily cleaning of the product path; CIP-compatible designs reduce the time required to just a few minutes. Wear parts relevant to planning: sealing belts, blades, seals on the jaws, and the wear elements of the dosing system\u2014the availability of these parts determines the system\u2019s uptime in the second and third years of operation.<\/p>\n

    Cost Factors: What Determines the Price of a Line<\/h2>\n

    The price of a VFFS line is determined by five factors: performance class (cycle rate and dosing system), degree of automation (recipe management, film web correction, roll change station), hygienic design (stainless steel, CIP, GMP-compliant design), component level (control system, drives, measurement technology), and scope of integration (conveyor technology, weighing control, gas flushing). To ensure a reliable cost estimate, the inquiry must include specific details\u2014product data sheet, format list, film samples, and target capacity.<\/p>\n

    Five Mistakes People Make When Shopping<\/h2>\n
      \n
    1. Buy based on rated power; plan based on continuous power:<\/strong> The 80 beats per minute listed in the data sheet are peak values\u2014the sustained performance is lower than that.<\/li>\n
    2. Consider the dosing system and the machine separately:<\/strong> The scale and bagging machine must be synchronized; a scale that is too large for a small format compromises accuracy.<\/li>\n
    3. Postpone the question regarding the slides:<\/strong> The foil is not a neutral part; it determines the sealing parameters and cycle rate.<\/li>\n
    4. Accepting a variety of formats without verification:<\/strong> Every format requires format parts and changeover time\u2014consolidating formats before making a purchase saves more than any discount negotiation.<\/li>\n
    5. Do not contact Service or Parts:<\/strong> Questions regarding spare parts inventory, response times, and remote maintenance should be addressed during the proposal phase.<\/li>\n<\/ol>\n

      VFFS or pre-made bags?<\/h2>\n

      The alternative to the tubular bag machine is the Bag-filling machine for pre-made bags<\/a>: A more sophisticated appearance, stand-up pouches, and zip closures from the pouch rack, but 30 to 60 pouches per minute instead of up to 80 cycles, and higher pouch costs. The detailed comparison can be found in the article VFFS or pre-made bags<\/a>.<\/p>\n

      Frequently Asked Questions<\/h2>\n

      How much does a VFFS machine cost?<\/h3>\n

      The price depends on the performance class, dosing system, hygiene design, component level, and scope of integration. A reliable estimate requires the product data sheet, format list, and target performance\u2014please request both the data sheet and a quote.<\/p>\n

      How long does the format change take?<\/h3>\n

      20 to 45 minutes with trained staff; significantly less time with tool-free quick-change format parts. The article on format changes describes the complete system.<\/p>\n

      What cycle count is realistic for my product?<\/h3>\n

      For free-flowing granules, 60 to 80 cycles per minute; for powders, 30 to 60 bags per minute; for bulk goods, depending on the product. Plan for 70 to 80 % of the rated power as continuous power.<\/p>\n

      Can a VFFS machine handle multiple bag sizes?<\/h3>\n

      Yes\u2014every format requires its own format set. The changeover time between formats ranges from 20 to 45 minutes; recipe changes without a format change can be completed in a matter of minutes.<\/p>\n

      Related pages:<\/strong> What is a vertical form-fill-seal (VFFS) machine?<\/a> | VFFS or pre-made bags<\/a> | Format Change on Packaging Machines<\/a> | Vertical Filling and Sealing Machine<\/a><\/p>\n

      \n

      Request technical specifications and a quote for your production line. Please specify the product, bag size, and target output (bags\/min.) \u2013 Request Technical Specifications and a Quote<\/a>.<\/p>","protected":false},"excerpt":{"rendered":"

      The vertical form-fill-seal machine forms, fills, and seals bags in a single pass\u2014at up to 80 cycles per minute with a filling accuracy of \u00b11 g. This guide walks you through the machine's design, filling process, selection, and operation.<\/p>","protected":false},"author":1,"featured_media":0,"comment_status":"","ping_status":"","sticky":false,"template":"","format":"standard","meta":{"_seopress_titles_title":"","_seopress_titles_desc":"VFFS-Ratgeber: Aufbau, Auswahl und Betrieb der vertikalen Schlauchbeutelmaschine \u2013 von der Formschulter bis zu 80 Takten\/Min., mit Folienkunde und Praxiswerten.","_seopress_robots_index":"","_seopress_robots_follow":"","_seopress_robots_imageindex":"","_seopress_robots_snippet":"","_seopress_robots_primary_cat":"","_seopress_robots_breadcrumbs":"","_seopress_robots_freeze_modified_date":"","_seopress_robots_custom_modified_date":"","_seopress_robots_canonical":"","_seopress_social_fb_title":"","_seopress_social_fb_desc":"","_seopress_social_fb_img":"","_seopress_social_fb_img_attachment_id":0,"_seopress_social_fb_img_width":0,"_seopress_social_fb_img_height":0,"_seopress_social_twitter_title":"","_seopress_social_twitter_desc":"","_seopress_social_twitter_img":"","_seopress_social_twitter_img_attachment_id":0,"_seopress_social_twitter_img_width":0,"_seopress_social_twitter_img_height":0,"_seopress_redirections_value":"","_seopress_redirections_enabled":"","_seopress_redirections_enabled_regex":"","_seopress_redirections_logged_status":"","_seopress_redirections_param":"","_seopress_redirections_type":0,"_seopress_analysis_target_kw":"","_seopress_news_disabled":"","_seopress_video_disabled":"","_seopress_video":[],"_seopress_pro_schemas_manual":[],"_seopress_pro_rich_snippets_disable_all":"","_seopress_pro_rich_snippets_disable":[],"_seopress_pro_schemas":[],"neve_meta_sidebar":"","neve_meta_container":"","neve_meta_enable_content_width":"","neve_meta_content_width":0,"neve_meta_title_alignment":"","neve_meta_author_avatar":"","neve_post_elements_order":"","neve_meta_disable_header":"","neve_meta_disable_footer":"","neve_meta_disable_title":"","neve_meta_reading_time":"","footnotes":""},"categories":[1],"tags":[185,204,184],"class_list":["post-78059","post","type-post","status-publish","format-standard","hentry","category-blog","tag-schlauchbeutelmaschine","tag-verpackungslinie","tag-vffs"],"_links":{"self":[{"href":"https:\/\/lintyco.de\/en\/wp-json\/wp\/v2\/posts\/78059","targetHints":{"allow":["GET"]}}],"collection":[{"href":"https:\/\/lintyco.de\/en\/wp-json\/wp\/v2\/posts"}],"about":[{"href":"https:\/\/lintyco.de\/en\/wp-json\/wp\/v2\/types\/post"}],"author":[{"embeddable":true,"href":"https:\/\/lintyco.de\/en\/wp-json\/wp\/v2\/users\/1"}],"replies":[{"embeddable":true,"href":"https:\/\/lintyco.de\/en\/wp-json\/wp\/v2\/comments?post=78059"}],"version-history":[{"count":0,"href":"https:\/\/lintyco.de\/en\/wp-json\/wp\/v2\/posts\/78059\/revisions"}],"wp:attachment":[{"href":"https:\/\/lintyco.de\/en\/wp-json\/wp\/v2\/media?parent=78059"}],"wp:term":[{"taxonomy":"category","embeddable":true,"href":"https:\/\/lintyco.de\/en\/wp-json\/wp\/v2\/categories?post=78059"},{"taxonomy":"post_tag","embeddable":true,"href":"https:\/\/lintyco.de\/en\/wp-json\/wp\/v2\/tags?post=78059"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}