Horizontal form fill and seal (HFFS) machines are packaging machines that form a pouch, fill it with a product, and seal it closed. These are go-to machines to speed up the packaging process, streamlining production for businesses because of their ability to neatly and efficiently put together products of all shapes and sizes.
In this guide, we’ll cover how HFFS machines work, the types of products they bag and fill, how they differ from a vertical form fill and seal machine (VFFS), and how you can determine if a HFFS is the right fit for your manufacturing needs.
What is a Horizontal Form Fill and Seal Machine?
A Horizontal Form Fill and Seal (HFFS) machine is a type of packaging equipment used to form, fill, and seal packages - typically flexible pouches or bags - in a horizontal orientation. In this machine, a roll of flat film is unwound and fed through the system, where it is shaped into a pouch. The product is then filled into the pouch, and the machine seals the pouch to create a finished package.
The process typically involves these key steps:
- Forming: The machine forms the pouch by folding and sealing the film into a pouch shape with an open top.
- Filling: The product (liquid, powder, or solid) is then filled into the open pouch.
- Sealing: The pouch is sealed, typically with heat, to secure the product inside.
5 Benefits of using an HFFS Machine
The many benefits of Horizontal Form Fill Seal machines make them popular choices in industries such as food packaging, pharmaceuticals, and consumer goods. Here are some of the primary reasons people choose to package with a HFFS machine.
1. High-Speed Production
HFFS machines are known for their ability to operate at high speeds, which significantly increases production rates. This makes them ideal for packaging large quantities of products efficiently, helping to meet high demand needs.
2. Flexibility in Package Design
HFFS machines can produce a variety of packaging formats, including flat pouches, stand-up pouches, and gusseted bags. This versatility allows manufacturers to offer different shapes and sizes tailored to the product and consumer preferences.
3. Ability to Handle Large or Bulky Products
Since the machine operates horizontally, it is well-suited for larger or heavier products that may be challenging to handle with VFFS machines. This makes it a good choice for packaging items like frozen foods, industrial products, and large snacks.
4. Precise, Secure Seals
The sealing process in HFFS machines is typically highly precise, ensuring strong, consistent seals that prevent leaks or contamination. This is crucial for maintaining product integrity, especially for products that are sensitive to air or moisture. The machine's ability to be precise helps cut down on waste too.
5. Minimal Product Damage
The smooth handling of products through the machine reduces the likelihood of product damage during the packaging process. This is particularly beneficial for delicate or fragile items that need careful handling.
How an HFFS Machine Works in 4 Steps
These steps cover how the HFFS machine operates from start to finish. Throughout the entire process, the machine is monitored by an automated control system that regulates factors like film tension, filling accuracy, sealing temperature, and speed. Operators can adjust settings as needed for different products or packaging sizes, ensuring consistent and high-quality output.
Step #1: Products are Fed to a Film Roll
A roll of packaging film (usually made of plastic or other flexible material) is unrolled and fed through the machine by a web puller. The film may be pre-printed with designs, branding, or product information.
Step #2 Wrapping and Sealing the Product
The product is fed to the formed pouch and then inserted into the pouch. The now-filled pouch is sealed to prevent leakage and secure the contents. This is typically done by heated sealing bars, which apply pressure and heat to the open ends of the pouch, causing the plastic film to fuse together.
Step #3 Cutting and Separation
Once the pouch is sealed, the HFFS machine moves the pouch to the cutting section. A knife or blade cuts the pouch from the continuous roll and creates individual packages.
Step #4 Discharge and Packaging
The finished pouches, now filled, sealed, and cut, are discharged from the machine. They may be stacked, packed into boxes, or placed on a conveyor for further processing or shipment.
What are the Differences Between Horizontal and Vertical Form Fill Seal Machines
The main differences between HFFS machines vs. VFFS machines lie in their orientation and the way they handle the packaging process. There are variances in the types of products, packaging sizes, and speeds suitable for each machine type.
While HFFS machines are best suited for three-sided seals or unique pouches (like granola, whey protein, and hot chocolate) and heavier items, VFFS machines create three-sided seals or pillow packs for items that easily fall into an upright pouch (like cereal and potato chips).
What Does a Horizontal Form Fill Seal Machine Make?
HFFS machines are highly versatile and can handle a wide variety of products, both solid and liquid, with different shapes and sizes. Some examples of products well-suited for HFFS machines include:
Food and Beverage Industry
- Frozen vegetables
- Cookies and muffins
- Baking flour
- Chocolate pieces
- Cocktails in pouches
Health and Personal Care Products
- Sample pouches of shampoo, conditioner, and lotion
- Vitamin pouches
Household Products
- Detergents
- Spray cleaning products
- Liquid chemical refills
Industrial Products
Small Items
- Seeds
- Small toy parts
- Small hardware
How to Choose the Right HFFS Machine
HFFS machines can cost anywhere from $5,000 to $1,000,000. Why the wide range? You may find a smaller machine that only handles one part of the operation (forming, filling, or sealing), or you may be able to get a full-service piece of equipment. Furthermore, each machine varies in output, speed, and the size of packages it can handle.
Machines with features like automatic film splicing, automated changeover, and real-time monitoring or quality control features (ex. vision systems for pouch inspection) cost more. While fully automated systems can reduce labor costs, they come at a premium price. This is why used equipment can be the most cost-effective choice. Buying used equipment can get you access to the manufacturers you want without the high price tag.
6 Questions to Ask When Buying an HFFS Machine
When searching for a high-investment piece of equipment, make sure you’re considering and asking detailed questions to ensure the HFFS meets your needs.
- Will an HFFS package the precise type of product you’re producing?
- Will an HFFS handle the specific type of material you’re using for the pouch?
- Will an HFFS package at the required product-per-minute pace?
- Can this HFFS handle the volume you require?
- Does the HFFS include the components of the process that are needed (form, fill, and/or seal)?
- What automation is included with the HFFS?
If you’re interested in purchasing a used HFFS machine or want to see if a HFFS machine is a good fit for you, we’d love to hear from you. Bid-on-Equipment prides itself on helping coordinate the sales of used form fill and seal machines and other types of used packaging equipment such as conveyors, wrappers, and vacuum packagers between buyers and sellers. We can work with you to find the piece of equipment that will best fit what you need.
