FFS Bagging Machine: Key Features and Industrial Application

Introduction

Achieving perfectly packed bags with precision and reproducible results is only possible with an FFS bagging machine. Filling 20 to 50 kg bags manually while handling powders or grains comes with health hazards and inconsistencies. Modern industrial grade FFS machines can pack 50kg of heavy material with highly repetitive quality and reliable packaging, especially with the tubular reel designs that eliminate the back seal. Premium grade machines can achieve up to 1200 bags per hour production rate.

FFS stands for Form-Fill-Seal. For factories that require inhouse made bags, they can use these machines to create the bag itself from a large roll of plastic. These bagging machines often work with Tubular Film, which is cut as per exact requirement, eliminating pre-fabricated bag overhead. All the motion within these machines is often created using servo machines driven with sophisticated control systems that make real-time adjustments based on produce weight or density.

In this article, we will primarily focus on industrial grade machines that come with the most precise control systems and advanced sensors for high accuracy and production rates. We will cover everything from basics to working mechanism, features, applications, comparisons, and buying tips to help readers make a purchase decision that will ensure lower TCO.

What is the FFS Bagging Machine

These are fully automated machines that, instead of using ready-made bags, take a large unbroken roll of plastic to create bags. These bags are then filled and sealed shut in a smooth sequence. Owing to their design, they work continuously. Depending on the material being handled and the weight of the bag, these machines can bag in pillow, gusseted, or M-type formats.

These are ideal for granular, dust-like substances or flat chips that flow freely. Owing to their PLC control, these machines can adjust the weight, filling, and sealing mechanism. The operator has to perform a simple set of instructions or basic programming to achieve the desired output. These come in a horizontal or vertical configuration. Horizontal machines are ideal for tubular reel film. Vertical machines rely on gravity drop for bagging.

How It Works

To understand how an FFS bagging machine works, we need to divide it into sections in a logical flow. Let's take them up one by one.

1. Rolling out Plastic

The machine has a massive roll of plastic attached. It pulls the plastic by unwinding it in a tubular or flat PE film form from the reel. The spool that holds the roll can be up to 1.5 meters wide in advanced machines. To ensure sheets are properly stretched, servo motors drive the rolls with precise tension control.

2. Shaping and Cutting the Bag

The second step in horizontal tubular systems is the folding of the sides into an M-type tube. The machine then performs the cutting. Depending on the length of the bag calculated from material storage requirements, the cutting length is decided. It is typically 650 to 900mm long for industrial applications. Through the application of heat or folding, the machine outputs open-mouth bags after this section.

3. Measuring and Pouring

As the open mouth bag moves down the line, an automatic weighing machine known as a net weigher or gravity/screw feeder drops the exact amount of product. These can be 20 to 50kg of material for a bag.

4. Closing it Tight

After filling, the bag moves to the hot metal press. It melts the plastic using instant high-temperature fusion. Immediately flow of cold air solidifies the bag into a ready to handle sealed bag.

5. Discharge

Before the bag leaves the machine, it needs some final touches. It includes strengthening the bottom corners using k-sealing or gusset forming. Also, squeeze out any trapped air and apply shipping details. Finally, the bags are cut, separated, and moved on to the belt.

Note: Unlike traditional machines, which do one step at a time. Horizontal tubular packaging systems to these at exact same time also called as parallel workstations. It reduces the cycle time significantly, making the process efficient with increased output. They also have in-line perforation tools to create easy-tear corners for quick opening without leakage risk.

Key Features

Now that we have the raw idea of how these FFS bagging machines work, we can move to the main section. These machines are versatile and feature rich to handle small snacks or industrial material bags. Let's see the features that make these systems worth installation for consumer or industrial raw material packaging.

Automatic Bag Forming

Everything in automated bulk bagging happens in a continuous manner. It gives these industries their high production rate. Everything from folding, filing, sealing, and cutting is done with +-3mm tolerance. There are no human interventions reducing the chances of human error entirely. These machines ensure every bag has a precise size using computerized servo motors. The operator can set the recipe changes via HMI (Human Machine Interface), which is usually a touchscreen. These machines handle PE or laminates as long as they have a melt index greater than 0.2.

Note: In case the factory requires a change in bag size, the operators can set up the whole machine for the new configuration in less than 10 minutes.

Form, Fill, and Seal Integration, Labor-Saving

Instead of having separate machines for each phase of the FFS bagging process, these automated bagging machines have all of them integrated into one unit. They typically have a less than 5 square meter footprint. It reduces labor work required in traditional setups to move material between machines and reduces manual handling by 80%.

Unlike a traditional setup, these machines can perform multiple tasks in parallel. One part of the machine is filling the bag while the other seals the previous one simultaneously. They are modular in design, which means they are easy to maintain. With automatic lubrication and self-diagnostic systems, these machines reduce downtime drastically.

High Speed

A standard Form-Fill-Seal bagging machine can handle 800 heavy bags of 20 to 50 kg every single hour. An industrial scale machine can output 1200 bags in an hour. A highly tuned machine with tubular systems can reach 2400 bags per hour. Their servo driven, parallel processing, continuous reel feeding, and auto splicing machines work continuously, even without the need for stoppage for roll changes. These are fitted with precision weighing sensors that ensure the machine is not over-filling or under-filling bags.

Precise Sealing

The machine uses the hot and cold cycle to create the ultimate seal that can handle 50kg of fertilizer with ease. As per an academic study published by Wiley, the overall strength of the seal depends on:

• How hot the metal gets
• How long the heat is applied (dwell time)
• Pressure applied to the film and the presence of contamination

These machines have industrial bag sealing technology that uses cornet k-sealing or gusset reinforcement to ensure that the bag stays intact. Applying controlled temperature, for an ideal dwell time with applied force and immediate cooling afterwards, makes packaging durable. Despite their durability, the FFS machine sealing process ensures that the bags are still easy to open. They also have variable-length perforations to allow quick opening of the bag, typically shorter near welds to block granules <0.2 mm.

Hygiene and Safety

To ensure that these machines are ready to work for hygiene sensitive applications, they are equipped with full stainless steel 304 for construction. This food-grade bulk packaging equipment prevents contamination and allows easy wash down. They have minimal operator contact, reducing microbial risk, and offer self-cleaning features. To ensure safety, there are emergency stops and fenced guardings.

Applications

Fertilizer

In bulk agricultural packaging, the machine needs to handle granular and pilled fertilizer quickly. They need to be dust free and poured with segregation on the basis of particle size. The plastic packaging acts as a barrier protecting the fertilizer.

Cement

Packing cement can be challenging. These cement bagging machines need to handle aerated powders while ensuring there is no air entrapment. For this, gusseted bags from tubular films are widely used. They allow the bags to lie flat pilled up over each other on a wooden pallet. For cement, they have special moisture ingress protection that can stop the production line as soon as it is detected.

Chemicals

For chemical handling, ensuring contamination free environment and machine operation is critical. FFS bagging machines can handle plastics that do not react with chemicals. They use premium grade SS to ensure protection against cross contamination. For chemicals that react with air (reactive substances), the machine can fill the bag and immediately flush the air with inert gas like nitrogen. The use of perforation tools is common in FFS machines for chemicals.

Food

When bagging elements like rice, sugar, seeds, or pet food, the machine needs to preserve freshness. The food should also not have a crust, and the machine should have high quality metal that does not rust. Only then can they pass all the food safety laws.

Advantages

Here are the top advantages of using a Form-Fill-Seal (FFS) machine:

• Savings on Supplies: Instead of using pre-formed bags, these machines use a continuous spool of plastic. It drops the packaging cost significantly and improves efficiency.
• Repetitive Quality: The industrial bagging equipment can repeat the pristine seal with superior consistency. The package won't burst open on delivery. The result is reduced customer complaints and increased satisfaction.
• Continuous Production: As there is no manual intervention required, the whole system runs smoothly. They are modular in design and designed for easy repairs. All the sections of bagging are integrated into a single machine.
• Eco-Friendly: The precise cuts ensure there is minimal plastic wastage. These machines are compatible with recyclable films.
• Worker Safety: The automated packaging ensures that the operator does not expose themselves to the dust. Moreover, they don't have to lift 20 to 50 kg loads.
• Flexible for Orders:  Factories need bulk packaging capacity with flexibility. It allows them to adjust to the seasonal changes and order requirements. Operators can change the shaping parts within 10 minutes.
• Electricity Saving: As these machines have horizontal parallel processing capability, they have higher energy efficiency per bag. In comparison, the traditional sequential methods keep machines running for longer with lower output.

Comparison with Other Machines

To fully understand how FFS machine has superior performance against other alternative machines that use traditional methods or inefficient processes.

Buying Considerations

As a factory owner, determining the required parameters like bags/hour, product density, and flow characteristics is vital for selecting these machines. There are machines that bag chips, and then there are ones that handle corrosive chemicals. FFS bagging machine manufacturers produce various grades for each type. Make sure you have the right machine planned for your project.

For sensitive applications, choose bulk packaging equipment that is in line with hygienic applications and use stainless steel construction and built-in vacuums for dust control. Look for PLC./HMI based operation with sensors that can provide Industry 4.0 connectivity. Consider a machine that has versatile options for different types of plastic handling, multi-product handling, high reel capacity, and easy changeovers.

Calculate the TCO (Total Cost of Ownership), not just the upfront cost, for comparison. Take into account energy use, labor costs, and maintenance intervals. Look for safety certifications and spare parts availability for long-term operations.

Aiming to Upgrade Your Factory

If you are looking to explore a highly customizable horizontal FFS bagging system, then consider Durzerd Machine. They offer machines that can work for fertilizer, cement, chemicals, and food industries. Their team of experts can provide personalized guidance for the factory process. Through their 20+ years of experience, they can analyze your requirements to provide a precise, high-speed automation system that will improve your profit margins. Feel free to contact us:

• Manufacturer: Durzerd Machine
• Tel: +86 15955114991
• Whatsapp：+86 15955114991
• E-mail: Business@durzerdmachine.com