Mastering Packaging Efficiency with Flow Wrappers - Lintyco

The company is a top-tier flow wrap packaging supplier globally, providing a one-stop solution for all packaging needs. Our specialized experts assist in choosing the right product for you.

Packaging machinery has significantly advanced over the last century to meet the modern food and consumer goods industry demands. Initially, packaging was manually done by skilled workers. Early machines were soon introduced to automate and expedite the process. Over time, the machinery has evolved with robotics and sensors, becoming increasingly complex, precise, and fully automated.

One vital packaging machine is the flow wrapper, which wraps products in film to create pouches or bags. Flow wrappers perform this by feeding film from a roll while conveying individual products into the film. The film is then sealed on all sides, forming a package around the product.

Flow wrappers offer numerous benefits over manual or other types of packaging. Capable of producing up to 200 packages per minute, they significantly enhance output. These machines ensure consistent package quality and shape with precise controls and settings. Initially designed for snacks and confectionery, flow wrapping now extends to various products, including pharmaceuticals. It effectively protects products, extends their shelf life, and provides appealing retail presentations.

What is a Flow Wrapper?

A flow wrapper is a machine that wraps products in film to form pouches or bags. Essentially, it feeds web film from a roll while conveying products into the moving film for wrapping.

The primary components and functions of a flow wrapper include:

• Film roll – Contains the plastic or foil sheet that forms the package.
• Conveyor belt – Moves products into the film wrapping area intermittently.
• Wrapping section – Wraps the film around the product and seals it.
• Sealing section – Uses heat, ultrasonic energy, or adhesive to seal the film edges together.
• Cutting section – Cuts the new package away from the rest of the film.

There are three main types of flow wrappers based on configuration:

• Tube flow wrappers form a tubular package around the product.
• Back wrap flow wrappers feed film from the rear, wrapping the product from behind.
• Side wrap flow wrappers feed film from one side, laterally wrapping the product.

How Does a Flow Wrapper Work?

The functioning of a flow wrapper can be broken down into six primary steps:

• Unwinding of film – Continuously unwinding packaging film from a roll.
• Product feeding – Feeding individual products into the film wrapping section using a conveyor belt.
• Wrapping – Inserting the product into the wrapping area as the film moves continuously.
• Sealing – Securing the film edges together to form an airtight seal around the product.
• Cutting – Separating the new package from the rest of the film.
• Dispensing of packages – Discharging the wrapped products onto a conveyor belt for further processing.

For different flow wrapper types:

In tube flow wrappers, the product drops into a tubular film sleeve, which is then sealed at the top and bottom. Back wrap flow wrappers feed film from behind the product, wrapping the front and sides. Side wrap flow wrappers feed film from one edge, rotating the product as needed for a complete wrap.

Key Features and Benefits of Flow Wrappers

Speed and Efficiency

Flow wrappers can operate at speeds of up to 200 packages per minute, significantly higher than manual methods. The continuous film feeding and automated product insertion ensure a steady wrapping rhythm for high output.

Versatility: Ability to Handle a Wide Range of Products

Flow wrappers can wrap products of various shapes, sizes, and weights, from rectangular blocks and cylindrical shapes to irregular products and multipacks. They are suitable for confectionery, snacks, food pouches, frozen products, and more.

Durability and Reliability

Commercial flow wrappers are built with durable components to handle high speeds and repetitive motions. Components like the film unwind unit, servo motors, conveyor belts, and sealing systems are designed for reliable performance with minimal downtime.

Cost-Effectiveness: Reduced Packaging and Labor Costs

Flow wrappers reduce material and labor costs compared to manual packaging. They use film efficiently with less waste, and automated operations require fewer workers per unit of output, offering a lower cost per package.

Quality of Packaging: Seal Integrity, Product Protection, and Presentation

Flow wrappers provide a consistent, high-quality seal around products, protecting against leaks, moisture, bacteria, and damage. The sealed pouches extend shelf life and offer better product presentation and branding opportunities for retailers.

Uses of Flow Wrappers across Different Industries

Food and Beverage Industry

Flow wrappers are widely used for packaging various food products like snacks, candies, bakery items, and frozen foods. Their high speeds and ability to handle irregular shapes make them suitable for various food items.

Pharmaceutical Industry

Flow wrappers are utilized for the packaging of pharmaceutical products such as tablets, capsules, test kits, and medical devices. They offer the precision, consistency, and product protection required for medications.

Consumer Goods Industry

In the consumer goods sector, flow wrappers package toys, stationery, household items, and small appliances, improving the product experience for consumers.

How to Choose the Right Flow Wrapper for Your Business

Understand your product and packaging needs:

Determine factors like product dimensions, weight, shape, required output, preferred pouch style, type of film, level of customization and automation needed, and regulatory compliance standards.

Evaluate the features and specifications of different wrappers:

Compare maximum product dimensions and weight limits, output, film width and roll diameter, types of conveyors, feeding systems, multi-lane options, sealing systems, cutting methods, and programmability.

Choose a reputable manufacturer:

Select a manufacturer with a strong record of reliability, durability, and after-sales service. Check online reviews and referrals from other businesses.

Consider your budget and maintenance needs:

Factor in your investment budget, total cost of ownership, spare parts cost, consumables, and regular maintenance needs.

Evaluate the after-sales service and support offered:

Research the warranty period, availability of spare parts, turnaround time for repairs, planned maintenance visits, remote support options, and training programs for operators.

Case Study: Success Story of a Business Using Flow Wrapper

Snackco, a small startup producing organic potato chips and tortilla chips, faced challenges with manual packaging. By investing in a flow-wrapping machine, they increased productivity by 400%, reduced labor costs by 60%, improved seal quality, reduced material waste, and lowered packaging costs by 45%, significantly enhancing their business efficiency.

Future Trends in Flow Wrapping Technology

Increased Automation and Integration with IoT

Flow wrappers will feature more sensors, controls, and automation, connecting to IoT for advanced monitoring, remote operation, and predictive maintenance.

Sustainability Through Eco-friendly Materials and Design

Future flow wrappers will use sustainable packaging materials like bioplastics and recyclable films, designed to minimize waste and maximize efficiency.

Customization and Personalization in Packaging

Technologies like digital printing will allow for customized graphics and messages on flow wrapped packages, meeting consumer demand for personalized packaging.

Predictive Maintenance and AI in Flow Wrappers

Sensors, data collection, and AI will detect performance issues, predict faults, and recommend maintenance, optimizing machine efficiency.

Robotics and Cobots for Flexible Production

Robots and collaborative robots (cobots) will be integrated into flow wrapping lines for flexible production capable of handling different product types and formats.

FAQ

Q: What Is a Flow Wrapper and Its Basic Functioning?

A: A flow wrapper is a packaging machine that wraps products in film to form pouches or bags. It operates by continuously feeding film from a roll, conveying individual products into the film to be wrapped, and then sealing and cutting to form a package.

Q: What Industries Commonly Use Flow Wrappers?

A: Flow wrappers are used in the food and beverage, pharmaceutical, and consumer goods industries, packaging products like snacks, confectionery, medications, and various household items.

Q: How Do You Choose the Right Flow Wrapper for Your Business?

A: Choose a flow wrapper by understanding your product and packaging needs, evaluating different wrappers' features, considering your budget, and assessing the after-sales service and support offered by the manufacturer.

Conclusion

Flow wrappers are an efficient, automated solution for packaging a wide array of products at high speeds, offering benefits like higher output, lower costs, and better seal integrity. Investing in flow wrapping technology significantly enhances packaging efficiency, productivity, and cost-effectiveness, making it an essential tool for forward-thinking businesses.

Lintyco, a pioneer in automated Flow Wrappers and end-to-end packaging systems, offers innovative packaging solutions for food, pharma, and other applications. Whether you need a new machine or want to upgrade your current packaging machine, Lintyco's experts, with over three decades of experience, provide optimal solutions backed by excellent consultancy and support.

What Type of Flow Wrapping Film Should I Use?

Finding the correct film type and usage is as important as choosing the packaging method. Flow wrapping accommodates many products, offering benefits like cost-effectiveness, minimal waste, and high-volume production. The process involves wrapping a product in a clear or printed film, forming a 3-sided seal package, resulting in a light and flexible package.

Several factors should be considered when selecting film:

• Dual films – Running dual films increases flexibility and efficiency.
• Selection – Balance quality, performance, efficiency, and cost. Match film choice to product and package characteristics.
• Characteristic questions – Consider Oxygen Transmission Rate (OTR), Water Transmission Rate (WTR), or Modified Atmosphere Packaging (MAP).
• Further factors – Sealing method, throughput, preferred pack style, product heat sensitivity, quality, budget, production volume, and sealing jaw profile.
• Product type – Flow wrapping is used for in-store produce bags, baked goods, candy, confectionery, meat, poultry, and more.

Common flow wrap films include:

• Polypropylene (PP) – Used for snack foods, candy, baked goods. Available as transparent, printed, or opaque film.
• Polyethylene (PE) – Includes low density, linear low-density, and high-density types. Used for stretch and shrink wraps, bakery goods, and frozen foods.
• Polyester Films (PET) – Often combined in laminations; used for metallicized packages and cook-in packaging.

The Right Seal:

• Common sealing elements: time, temperature, and pressure.
• Jaw seals: Consider jaw sealing methods and types.

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• Seal performance – Adjustments needed when variables change.
• Hot and cold film seal – Depends on product characteristics, material costs, production throughput, required seal strength, and film barrier characteristics.
• Cold seals – Produced by pressing together films using a base material with a glue layer, suitable for heat-sensitive products.
• Heated seals – Best for high integrity; temperature range is crucial.