Streamlining Packaging: An Introduction to Flow Wrapping Technology and Tailored Solutions

In today’s fast-paced manufacturing and retail environments, efficient and effective packaging is paramount. One widely adopted solution for packaging a multitude of products is flow wrapping. This automated process, also known as horizontal form-fill-seal (HFFS), encases items in a continuous sheet of packaging material, creating a sealed and often aesthetically pleasing final product. These machines are essential primary packaging solutions across diverse sectors.

The Mechanics of Motion: How Flow Wrapping Works

At its core, flow wrapping is a dynamic process. Products are typically fed along an infeed conveyor system, designed to handle various product sizes and shapes, in a single line. Simultaneously, a roll of packaging film – which can range from clear plastics and laminates to sustainable paper-based options – is unwound. A film unwind and tension control system guides the material to a forming shoulder, which shapes the film into a tube around the incoming items.

As the product moves through this tube of film, a sealing system creates a longitudinal fin seal. Following this, a set of end-sealing jaws, often combined with a cutting mechanism, creates transverse crimp seals at both ends of the product, simultaneously separating it into an individual unit. The result is a neatly enclosed item, often referred to as a “pillow pouch.” An outfeed conveyor then transports the finished wrapped products.

Key Advantages of Employing Flow Wrapping

Manufacturers across various sectors opt for flow wrapping due to its numerous benefits:

• Speed and Efficiency: Flow wrapping machines are engineered for high-volume production.
• Product Protection and Shelf Life: The sealed environment safeguards products and can extend shelf life, especially with options like Modified Atmosphere Packaging (MAP).
• Versatility in Application: A broad spectrum of food and non-food products can be flow-wrapped.
• Material Flexibility and Branding Opportunities: Various films can be used, including sustainable options, with ample space for branding.
• Cost-Effectiveness: Optimised material usage and reduced labor lead to lower packaging costs.
• Tamper Evidence: Sealed packages clearly indicate if tampering has occurred.
• User-Friendly Operation and Maintenance: Modern machines often feature intuitive controls and designs that facilitate cleaning and maintenance.

Choosing the Right Machine: The Importance of Expert Guidance

Selecting the appropriate flow wrapping machine is crucial for maximising efficiency and achieving desired packaging outcomes. Record Packaging Systems emphasise providing customers with outstanding service and support, ensuring that the machinery is tailor-fitted to each client’s unique needs. Sales Director, Robert Murphy, oversees office operations in Manchester, focusing on maintaining high service standards. This dedication to bespoke solutions underscores a key industry principle: the right machine depends heavily on the specific application.

Record Packaging offers a range of machines, including specialised Box Motion Flow Wrap machines. These are distinct from rotary motion wrappers and are particularly well-suited for products requiring longer sealing times, hermetic seals (often necessary for MAP), or for delicate or difficult-to-handle items. Key features of their Box Motion machines often include:

• Precision Sealing: The “box” or rectangular motion of the sealing jaws allows for extended sealing dwell time compared to rotary jaws, ensuring a high-integrity seal, which is vital for freshness and preventing leaks, especially with barrier films.
• Versatility for Difficult Products: Ideal for taller, heavier, or awkwardly shaped items that might be challenging for other types of flow wrappers.
• MAP Compatibility: Excellent for creating Modified Atmosphere Packages, extending the shelf life of fresh foods.
• Robust Construction: Designed for durability and consistent performance in demanding production environments.
• User Interface and Control: Often equipped with advanced PLC controls and user-friendly HMIs for precise parameter setting and recipe management.

Their offerings also include Rotary Motion Flow Wrap machines, which are generally suited for higher speed applications with products that are more uniform and require less dwell time for sealing.

Considerations for Implementation

When integrating a flow wrapping system, factors to consider include:

• Product Characteristics: Size, shape, fragility, and product state (individual, trayed).
• Production Speed Requirements: Matching machine capability (e.g., box motion for strong seals, rotary motion for high speed) to output needs.
• Packaging Material: Compatibility with the machine, product, and sustainability goals.
• Sealing Technology: Heat sealing, cold sealing, box motion, or rotary motion jaw systems.
• Machine Configuration: Inverted (film fed from below) or standard (film fed from above) designs.
• Additional Features: Date coding, labeling, automatic feeding, gusseting, or specific cut types.

As Robert Murphy’s role in ensuring Record Packaging Systems delivers outstanding service and support suggests, “Selecting the right flow wrapper isn’t just about the machine’s specs; it’s about understanding the intricate needs of the product, the desired presentation, production environment, and long-term operational goals. A thorough assessment and expert guidance are key to a successful packaging solution.”

Advancements in Flow Wrapping

The technology continues to evolve with increased speeds, improved sealing integrity, more sophisticated control systems (often servo-driven), and a strong focus on accommodating sustainable and recyclable packaging materials.

In Conclusion

Flow wrapping technology offers a robust, versatile, and highly efficient solution. The availability of different machine types, such as the specialised Box Motion wrappers offered by companies like Record Packaging, alongside more conventional rotary motion machines, allows businesses to find a system truly tailored to their needs. Expert consultation, as emphasised by the customer-centric approach of firms like Record Packaging, is vital in navigating these choices to ensure optimal performance, product integrity, and efficiency in today’s demanding markets. Ready to find out more? Contact us today.