Common Mistakes to Avoid When Using a Vertical Form Fill Seal Machine

Vertical Form Fill Seal machines (VFFS packaging machine) are a cornerstone in modern packaging, offering flexibility and efficiency. But even the best machines can run into trouble if they're not handled properly. As a manufacturer who's worked extensively with these machines with 12 years, we’ve seen many operators face challenges that could be easily avoided. In this post, we’ll share the most common mistakes and practical tips to help you keep your VFFS packing machines running smoothly.

1. Choosing the Wrong Film

One of the first mistakes we see is using the wrong type of film. Not every film works with every product or sealing method. If you're packaging something delicate or require a specific barrier, your film needs to match those requirements.

Common Mistake:

Using a film that’s too thin or doesn’t suit your product can lead to tears, weak seals, or even jam the machine.

Solution:

Pick the Right Film for the Job: Consider the thickness, material, and compatibility with your product. If you're not sure, consult your machine manufacturer or supplier for recommendations. Also, run a test batch before going into full production—better safe than sorry! And the single layer film should choose specific sealing jaw for better sealing.

2. Improper Machine Setup

Setting up your VFFS packaging machine correctly is crucial, yet it's something many operators rush through. Each run might require different settings for temperature, sealing pressure, or film tension depending on your product and the film type.

Common Mistake:

Not checking or adjusting the machine's settings before starting the production run.

Solution:

Always Double-Check the Settings: Make sure the temperature, pressure, and film tension are set for the specific film and product. Regular calibration of these settings ensures consistent and high-quality results.

3. Inaccurate Product Weighing

Getting the right product weight into every bag is non-negotiable, especially if you’re dealing with food products. Overfilling or underfilling leads to waste or customer complaints.

Common Mistake:

Manual feeding or incorrectly configured weighing systems result in inconsistent product amounts.

Solution:

Use Automated Weighing: If you're still manually filling, it’s time to upgrade. Automatic weighing systems, like multihead weighers, can save you time and ensure accuracy. Regularly calibrate your system to keep everything on track.

4. Skipping Maintenance

One thing you should never overlook is maintenance. We often say, it's better to be cautious than regretful later. Skipping maintenance is a sure way to face downtime, product quality issues, and even damage to your machine.

Common Mistake:

Failing to stick to a maintenance schedule leads to wear and tear that can quickly get out of hand.

Solution:

Regular Maintenance Is Key: Make sure to clean, lubricate, and inspect your machine at regular intervals, as per the manufacturer's guidelines. Also, train your staff to spot early signs of wear—this can save you from costly repairs down the line.

5. Incorrect Sealing Parameters

The sealing process is perhaps the most critical part of packaging. Too hot, and you'll burn through the film; too cool, and the bags will burst. Finding that sweet spot is essential for a strong, reliable seal.

Common Mistake:

Using the wrong sealing temperature or pressure for the film type and product.

Solution:

Fine-Tune Sealing Settings: Different films require different settings. Always adjust your machine based on the thickness and type of material you're using. Regularly test your seals during production to ensure strength and consistency.

6. Inconsistent Product Feeding

A steady product flow is essential, whether you're feeding manually or using an automatic system. Interruptions can result in underfilled or overfilled bags and wasted product.

Common Mistake:

Poor feeding causes inconsistent filling and packaging errors.

Solution:

Ensure Smooth Product Feeding: If using manual feeding, make sure operators are trained to maintain a consistent flow. For automatic systems, use the appropriate hoppers and ensure that product is evenly distributed to avoid clogs or gaps.

7. Lack of Operator Training

Even the best equipment will fail if your operators aren't properly trained. We often see companies invest in high-quality machines but skimp on training. This is a recipe for frequent errors, reduced efficiency, and safety risks.

Common Mistake:

Undertrained operators may not fully understand how to set up, run, or troubleshoot the machine.

Solution:

Invest in Operator Training: Proper training for all operators is essential. Ensure they understand machine setup, troubleshooting, and safety protocols. Regular refresher courses can help keep everyone sharp.

8. Overloading the Machine's Capacity

Every machine has its limits, and pushing it beyond those limits won’t end well. Overloading the machine can cause increased wear, breakdowns, and even compromised packaging quality.

Common Mistake:

Exceeding the machine's rated capacity leads to frequent breakdowns and performance issues.

Solution:

Respect the Machine's Capacity: Stick to the manufacturer's guidelines for throughput. If you consistently need more output than your machine can handle, it’s time to think about upgrading.

9. Misaligned Forming Tube and Sealing Jaws

If your forming tube and sealing jaws aren’t aligned correctly, you're in for a rough ride. Misalignment can cause skewed bags, poor seals, and wasted material.

Common Mistake:

Not checking the alignment during machine setup or after maintenance, resulting in faulty packaging.

Solution:

Check Alignment Regularly: Make sure the forming tube and sealing jaws are perfectly aligned before you start the machine. Periodically check for signs of misalignment, such as skewed bags or weak seals, and correct it immediately.

10. Ignoring Wear and Tear on Critical Parts

Over time, parts like sealing jaws, cutting blades, and belts wear down. If not replaced in time, this can lead to bigger issues like machine breakdowns or poor packaging quality.

Common Mistake:

Failing to replace worn parts promptly, causing performance and quality issues.

Solution:

Replace Worn Parts Regularly: Monitor your machine for signs of wear and replace parts as needed. Having spare parts on hand can save you a lot of time when replacements are necessary.

Conclusion

The Vertical Form Fill Seal machine is a workhorse in the packaging industry, but only when it’s used and maintained correctly. Avoiding these common mistakes can save you time, money, and stress. From selecting the right film to properly maintaining and calibrating your machine, paying attention to the details ensures smooth operation and top-quality packaging.

At Smart Weigh, we're not just vertical form fill seal packaging machine supplier—we're partners in your flexible packaging needs success. Need advice or looking to upgrade your equipment? Feel free to reach out to us anytime.

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