Packaging machine first time buying guide

  Our first-time buyer's guide will help you understand the different types of packaging machines, answer the most common packaging machinery questions, and provide tips on how to make the best packaging automation decision for your business.

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  Frequently Asked Questions

1.How much does packaging equipment cost?

There is no quick, easy answer to this question. Packaging machinery is specific to the customer, so arriving at 'standard pricing' isn't usually practical. But we can provide a range: For fully automated systems, you can expect to pay in the mid-to-high five figure range all the way up to millions of dollars.

Pricing largely depends upon your unique needs: The products you want to package, the speeds you would like to achieve, your bag styles and sizes, the complexity of your process, and how quick you need the machine delivered.

Generally, the more complex, customized, or high-speed the packaging process is, the more you can expect to pay.

 2.How easy is it to operate packaging equipment?

The good news is that as long as your packaging system isn't hyper-customized, the equipment is pretty easy to use! Most of Samfull's equipment does not require advanced technical knowledge to operate.

Modern packing machines have intuitive full color touch screen interfaces. And if you need to change the machine over to accommodate different bags, it can be done without tools.

Still worried about the learning curve? Ask your representative or contact our service department for training options. Our expert technicians would love to show you how it's all done.

  3.What types of packaging machines do you offer?

Samfull offers a variety of flexible packaging machines that can satisfy almost any requirement.

We offer PREMADE POUCH FILLING AND SEALING MACHINES that are loaded with preformed bags which are then filled with product and sealed shut. These machines are easy to learn and operate and can be run with low-skilled labor. The end product they produce has a premium look. Adjusting these machines for new bags is simple, so they are great for companies that have varied bags sizes and short runs.

We also offer VERTICAL FORM FILL SEAL (VFFS) PACKAGING MACHINES. This equipment forms bag shapes, fills the bags with product, and seals them shut, all in a vertical fashion. These machines are established technology capable of high speeds and economical in cost. They do, however, require a higher level of expertise to operate and troubleshoot and are best for dedicated lines without much variation in product and bag styles.

Another category of equipment we offer is multi-lane SACHET and STICK PACK MACHINES. They work in a similar manner to VFFS machines but produce multiple bags at once via multiple packaging lanes.

Finally, we offer cartoning equipment that erects cardboard cartons, counts out a number of packages, places the bags into the cartons, and seals the cartons shut.

  4.What's the difference between semi-automatic and fully automatic packaging systems?

A fully automated packaging system is optimized for high speeds and minimal human involvement. These solutions are best for companies that run a high number of products with relatively low variation. A fully automated line could include things like equipment to feed the product to the system, a scale to weigh the product, and a machine to place the product into bags. Automated systems provide a high level of accuracy and consistency, but require a larger upfront investment.

A semi-automatic packaging system still requires a substantial level of human labor. For example, a company could use an automated scale to weigh the product, but require a human to dispense the product into bags and seal them. Semi-automatic packaging lines are a great place to start if you're not quite ready for full automation. In many cases, individual pieces of a semi-automatic line can be integrated at a later date with other equipment to create a fully automated system. Overall, semi-automatic packaging lines have a much lower cost of entry, but are slower and less accurate than fully automated systems.

  5.Can one packaging machine handle different bag styles, sizes, and products?

The short answer is "Usually, yes." Adjusting a machine to accommodate different bags is called changeover, and it can take from minutes to hours depending upon many variables.

The longer answer: Sometimes a one-size-fits-all machine isn't the best choice. The more varied your needs are, the more it may make sense to invest in multiple systems or automate only certain parts of the process. Reason being, packaging machines are optimized to run within certain parameters. If your needs are varied, accommodating those variations within machine parameters can be complex, costly, and inefficient. It can sometimes be better to have a machine that does one thing really well than a machine that does many things 'just okay'.

  6.What's the difference between rollstock film and premade bags?

Knowing the packaging material format you require informs which machinery the equipment manufacturer recommends.

For more information, please visit VFFS Packing Machine.

Here are descriptions of two major flexible packaging formats:

Rollstock film is a long, flat sheet of (usually plastic) packaging material that is wound around a hollow core. It is usually pre-printed with graphics. This large roll of film is loaded onto the back of a form fill seal machine which then forms it into bag shapes, fills the bags with product, and seals them shut. Rollstock film is generally economical in cost per bag and can run at high speeds.

Premade bags arrive at the packaging facility already formed into their end bag shape. They are loaded into a pouch fill and seal machine that fills them with product and seals them shut. Premade bags have a premium look that can't be beat, but usually cost more per impression than bags created from rollstock film.

  7.What are packaging machine fillers/dosers and do I need one?

The packaging machine itself does not measure or dispense product. Instead, integrated filling or dosing equipment measures out discrete quantities of product into the packaging machine to be dispensed into the bags. Fillers usually sit above or off to the side of the packaging machine.

Depending upon your needs, different fillers will be recommended. Here are some of the most widely used:

Auger fillers are often used for powder products. This equipment uses a long screw-like mechanism to measure product into bags.

Multi-head scales are often used for solid products. These highly accurate systems use weigh buckets to weigh out product before dropping it into bags.

Liquid pumps usually use a piston mechanism to measure specific volumes of liquid product into bags.

You do not have to have a filler to be able to use a packaging machine. However, if a filler is not present, a human must stand-in. This will limit the system's speed and accuracy. Most of our clients integrate their packaging machine with a filler.

  8.How fast can packaging equipment run?

Packaging equipment speeds are usually represented by bags per minute (BPM), which is how many finished bags can be completed per minute. Machines will usually be rated for a maximum number of bags per minute. Generally, automated flexible packaging machines can be rated for anywhere from 10 - 100 bags per minute.

Actual production speeds, however, depend on many factors. Your product properties, bag sizes and styles, plant environment, and technical skill of operators will all factor in to actual speeds.

The best way to estimate actual production speeds is to send in film/bag and product samples to the packaging machine manufacturer for testing.

This is a question we get asked all the time. Whether you’re a new business just starting out and have never bagged your product or you’re a seasoned operation that has just never automated the bagging process, the choices out there are seemingly endless. We’ll attempt to provide some clarity and hopefully answer questions you might have about this type of packaging machine.

So, what is a bagging machine?

Just look at your grocery store shelves. If it’s not in a wrapper, bottle or carton, chances are it’s in a bag. And even some of those items are placed in a bag after their initial packaging. Liquid or solid, food or component, medical or pharmaceutical, you will find bagging machines in a variety of configurations based on product size and weight.

A pouch filling machine can open your premade bag and then both close and seal the bag after your product is deposited. Other bagging machines will form, cut and seal from a roll of film to produce the bag. Either way, this is just one step of the overall packaging process. There is a pre-filling stage where your product is weighed or counted and prepared for bag filling and then there is usually some process for moving the bags after they are filled including conveying, labeling, check weighing, case filling and even palletizing.

What do you mean by premade bag versus a roll of film?

If you are already bagging your product, then this one is easy, so bear with us for a second. A premade bag, or pouch, is fully formed on three sides and just needs to be filled and sealed prior to moving on to the next step of the packaging process. A bag made from a cylindrical roll of film needs to be formed, filled and sealed on 3 or 4 sides prior to the next step. Each type of machine has its advantages. The amount and consistency of your product may dictate which process you need, and one machine may work better than another with some products. Cost and facility space issues can also be important factors.

How can I tell the difference?

You’ll know a premade pouch filling machine because there is no place to load a roll of film onto a spindle. Instead, premade bags are conveniently loaded into the machine from a magazine that can be adjusted to the allowable minimum and maximum bag sizes. A vertical form, fill and seal machine (VFFS) or a horizontal form, fill and seal machine (HFFS) needs a spindle to handle a roll of film equal to the maximum bag width the machine can accommodate. They will also have a noticeable collar, shaped somewhat like a plow, to open the flat film into a fillable shape.

What is the optimal bagging machine for me?

It really depends on several factors. Here are a few variables to consider:

• • Budget. In general, the entry price for a premade pouch filler and a VFFS machine are competitive while an HFFS machine entry price will be higher. Keep in mind that the price of a premade bagging machine does not account for the additional cost of premade packaging. You will typically pay 30% more for your premade pouches than you will for roll stock film. And while you may have some packaging waste while you fine-tune the size of the bag made with a VFFS or HFFS machine, premade pouches require more inventory space and can be left unused if you move to a different size bag. Make sure you research the minimum and maximum bag sizes and speeds each type of machine can handle when it comes to your product. Make sure to factor in material costs and potential savings based on each machine type.

• • Complexity. The good news is most packaging machines do not require highly skilled operators once they’ve received comprehensive training. But they will require a higher level of technical expertise within your operation for ongoing maintenance and adjustments. With that said, an HFFS machine is typically a larger, servo-driven unit capable of producing a larger variety of bag and pouch styles within one machine. The ability to produce and seal your own 3-sided, 4-sided, pillow or stand-up DOY pouches of varying sizes at high-speed with options like zipper closure and spout insertion can make these machines well worth the higher price if you need that flexibility. But that does not mean premade pouch filling machines and VFFS machines are not complex or cannot deliver high production rates, they are typically more specialized in terms of bag size, type and speed. They may be more affordable and consistent options for smaller operators just starting out. They may also be useful for those with a uniquely shaped premade pouch or a need to bag larger or heavier product that only a larger VFFS machine can accommodate.

• • Speed. Most reputable packaging machine suppliers have a variety of VFFS, HFFS and premade baggers that can produce up to 50 packages per minute. Some may even have models that fill up to 100 packages per minute. If speed is a priority for your company, be realistic about your bags type, desired size and end weight. If a supplier has a machine in each category that can accommodate your product at the size, weight and speed you need, then what are your other criteria? Cost? Appearance? Sanitization? While VFFS and HFFS machines can generally deliver higher speeds, make sure that speed really is the most important factor for you, all other factors being equal.

• • Your Product. Let’s say, just as an example, you need to fill 30 pounds of dog food into a bag. Chances are you won’t be using a premade pouch filler that can typically only handle a bag 10-12 inches wide. You’ll need a bagging machine that can allow you to fill a wider bag with heavier material that can be appropriately sealed and that’s probably a job for a VFFS machine. On the other hand, if you need to fill small pet treats into a stand-up resealable bag, a 10- or 12-inch bag width may work just fine so you need to look at the other machine variables like budget, complexity and speed.

• • Marketing. Since premade pouch filling machines utilize predesigned and precut pouches, you can expect a consistent, attractive package for your product every time. You can also expect the same precision out of the larger HFFS machines since they can typically replicate the complexity of premade pouches with roll stock film. But with an HFFS machine, you also have the flexibility to vary the shape, seal and form of your bags within the maximum allowable width without having to buy a separate inventory of bags. Also keep in mind that many packaging machine manufacturers feature custom machines for side-loading product into premade bags, such as wrapped bars for the snack food industry. There are also machines to fill and vacuum seal premade wicket bags as commonly seen in foodservice packaging for fresh produce and meat.

What Else Is There?

These are just a few our observations about automatic bagging machines and some of the factors to consider before purchasing your machine. You should also make sure to factor in considerations such as:

• Labor savings,
• Access to service tools and maintenance plans,
• Availability of spare parts,
• Ease of changeover,
• Facility space and layout; and,
• Supplier reputation and longevity in the industry.

And maybe there are other factors on your list we have not thought of.  Weigh them all out and then make the decision that is right for your product and your future.

Learn More About Your Options

If you still need help, we’re here for you. We’re good listeners. And we’re pretty good solvers too. We have a 30-year record of problem-solving sessions and free consultations typically resulting in long-lasting partnerships. We would be honored to help you build a bagging solution for your product.

Are you interested in learning more about Automatic Vertical Packing Machine? Contact us today to secure an expert consultation!