VERTICAL FORM FILL SEAL MACHINES
VFFS Packaging Solutions Built Around Your Product
Unified Flex designs packaging solutions around your product’s unique behavior. From free-flowing liquids to granular and sticky powders, each material requires specific handling and sealing conditions. Our systems ensure every package is consistent, dependable, and ready for the market.
Our vertical form fill seal (VFFS) machines are engineered to fit your product, your plant, and your process. Every design reflects our principles of being simple, reliable, and robust, because packaging should never be the bottleneck in your operation.
Proven Across Diverse Product Behaviors
Every product brings unique packaging challenges, shaped by flow, viscosity, or particle structure. Unified Flex has delivered solutions across 20+ industries, from food, beverage, and nutraceuticals to pharmaceuticals, pet food, personal care, and industrial applications. This breadth of experience means we’ve solved challenges like yours before, and we know how to engineer packaging systems that deliver consistent, efficient, and reliable performance.
Applications That Speak for Themselves
Viscous or Semi-Viscous Liquids
Perfectly packed popsicles, a testament to our turnkey packaging expertise for viscous products.
Precision piston filling meets clean, consistent sachet packaging, an AP-140 setup built for efficient output, easy control, and reliable seals across multiple bag styles.
Granular & Powder Products
Big flexibility in a compact footprint, watch the AP-140 with auger filler run stick packs, 3-side seal, 4-side seal, and pillow bags with smooth, reliable sealing.
Solids
From snacks to powders, the Vertobagger Hornet keeps output steady, servo-driven belts, photo sensor seal control, and up to 80 pouches per minute.
From powders to granules, the AP-180 keeps pouch packaging simple, flexible bag types, consistent performance, and minimal downtime by design.
Packaging Challenges We Solve
Every manufacturer faces recurring hurdles that drain time, waste product, and erode confidence. We address these challenges head-on, turning them into dependable outcomes.
- Frequent changeovers — switching SKUs or bag sizes without losing hours of production.
- Training new operators — intuitive controls and simple setups that shorten the learning curve.
- Downtime risk — keeping uptime high with precise, durable parts that minimize rework.
- Seal integrity — consistent, high-quality seals that prevent leaks, recalls, and unhappy customers.
- Film tracking issues — reliable film handling for clean, straight packages every run.
- Hygiene requirements — washdown-friendly stainless steel designs that reduce contamination risk.
- Maintenance complexity — built-in diagnostics and robust frames for faster troubleshooting and less upkeep.
Our role is simple: remove these frustrations so your operation runs smoothly, safely, and profitably.
Engineered Features, Tangible Benefits.
Every feature on a Unified Flex machine exists to remove complexity and build confidence in your packaging line.
VFFS Machine Features
What it Means For You
Our Process:
Structured, Transparent, Reliable
When you work with Unified Flex, you get more than a machine. You get a process that minimizes risk:
- Understand your product & goals
- Engineer the right design for your plant requirements
- Test every system in-house before shipment
- Factory Acceptance Test (FAT) with your team
- Install, train, and support with North American service & parts
Why Manufacturers Choose Unified Flex
- North American-built machines - Fast access to parts and support.
- Process-driven engineering - Consistency, not improvisation.
- Proven experience across industries - Food, pharma, medical, industrial.
- Focused on reliability - No lofty promises, just dependable results.
- Partnership approach - We align with your long-term goals
VFFS Intermittent Motion Machine - Premium
VFFS Vertobagger Hornet XL
minute max.
bag width
bag length
VFFS Vertobagger Hornet
minute max.
bag width
bag length
VFFS Vertobagger Hornet Washdown
minute max.
bag width
bag length
VFFS Intermittent Motion Machine - Economy
Auto Pouch Bagger AP-140
minute max.
bag width
bag length
VFFS Vertobagger Maverick
minute max.
bag width
bag length
Auto Pouch Bagger AP-180
minute max.
sachet width
sachet length
VFFS Vertobagger Falcon
minute max.
bag width
bag length
Stick Pack Machines
Auto Pouch Bagger AP-140 Stick Pack
minute max.
stick pack width
stick pack length
Multilane Stick Pack – MSP 300mm
minute max.
stick pack width
stick pack length
Multilane Stick Pack – MSP 440mm
minute max.
stick pack width
stick pack length
Multilane Stick Pack – MSP 800mm
minute max.
stick pack width
stick pack length
Sachet Machines
Auto Pouch Bagger AP-140 Sachet
minute max.
sachet width
sachet length
Auto Pouch Bagger AP-180 Sachet
minute max.
sachet width
sachet length
Multilane Sachet Bagger – MSB 406mm
minute max.
sachet width
sachet length
Multilane Sachet Bagger – MSB 508mm
minute max.
sachet width
sachet length
Multilane Sachet Bagger – MSB 813mm
minute max.
sachet width
sachet length
VFFS Continuous Motion Machines
VFFS Vertobagger 2.0
minute max.
bag width
bag length
VFFS Vertobagger 2.0 Ultrasonic
minute max.
bag width
bag length
Machine Knowledge Hub
VFFS in Industry
Frequently Asked Questions
What is a VFFS machine?
A Vertical Form Fill Seal machine (VFFS) is an automated packaging system that forms, fills, and seals bags in a continuous vertical process. It starts with a roll of film, which is pulled into the machine, shaped into a bag, filled with the product, and then sealed.
VFFS machines are valued for their efficiency, speed, and versatility, making them a preferred choice across industries such as coffee, dairy, meat and cheese, cosmetics, and more. They can handle a variety of bag styles, product types, and packaging materials, ensuring consistent and high-quality packaging.
Want to improve your packaging process? Contact us today to find the right VFFS solution for your business.
How does a VFFS packaging machine work?
A Vertical Form Fill Seal machine (VFFS) efficiently automates the packaging process through the following streamlined steps:
9-Step VFFS Packaging Process
The VFFS process is fast, efficient, and precise, running multiple cycles per second to create sealed pouches. Here’s a breakdown of how it works:
1. Film Unwinding (Rollstock Loading)
A roll of flexible packaging film (plastic, laminated film, or foil) is loaded onto the mandrel and unrolled through the carriage assembly. Different machines have varied methods for film transportation.
2. Tension Control (Dancer Arm Movement)
A dancer arm moves up and down to maintain consistent tension as the film is fed through the machine, preventing wrinkles and misalignment.
3. Printing (Optional)
An integrated printer applies lot codes, expiration dates, barcodes, or branding as the film moves through the system.
4. Film Registration (Eye Mark Detection)
A photoelectric sensor detects eye marks (registration marks) printed on the film to ensure accurate positioning for precise cutting and sealing.
5. Film Alignment (Tracking & Adjustment)
A film tracking sensor confirms proper positioning. If misalignment occurs, an actuator automatically corrects the film’s path to maintain accuracy.
6. Forming the Bag
The film is then fed around a forming collar, shaping it into a cylindrical tube. A vertical seal is then created using heat sealing or ultrasonic sealing, forming either a lap seal or fin seal.
7. Bag Size Configuration
The width of the pouch is determined by the forming collar size. The length of the pouch can be adjusted anytime using machine settings. Intermittent motion machines have small pauses between each cycle, while continuous motion machines run non-stop at higher speeds.
8. Product Filling
The bag remains open at the top while the product is dispensed through a filling system, which varies based on the product type:
- Auger filler – for powders (e.g., coffee, flour).
- Volumetric cup filler – for granules (e.g., rice, beans).
- Piston pump – for liquids and pastes (e.g., sauces, gels).
- Multi-head weigher – for precision weighing (e.g., snacks, candies).
9. Sealing & Cutting (Final Step)
A horizontal seal is applied to close the top of the pouch. A cutting mechanism separates individual bags or keeps them in strips.
This automated, high-speed process ensures consistent, hygienic, and efficient packaging, making VFFS machines ideal for food, pharmaceuticals, cosmetics, and other industries.
Looking for an efficient packaging solution? Contact us today to explore how our VFFS machines can optimize your production process!
Are VFFS machines easy to maintain?
Yes, VFFS machines are designed for easy maintenance, but regular servicing is important to ensure optimal performance and longevity. Routine maintenance typically includes:
- Cleaning: Regularly removing product residue and dust to maintain hygiene and prevent malfunctions.
- Inspecting & Replacing Sealing Components: Checking sealing jaws, heating elements, and gaskets to ensure consistent and strong seals.
- Lubricating Moving Parts: Applying lubrication to rollers, gears, and mechanical components to reduce wear and friction.
- Checking & Calibrating Sensors: Ensuring photoelectric sensors, film tracking, and filling systems are properly aligned for accurate packaging.
- Replacing Worn-Out Parts: Monitoring belts, blades, cutting knives, and sealing jaws and replacing them as needed to prevent breakdowns.
Many modern VFFS machines come with automated diagnostics, error detection systems, and easy-access panels, making maintenance straightforward and minimizing downtime.
Looking for an easy-to-maintain VFFS machine? Contact us today to explore our VFFS packaging solutions for your packaging needs!
What are the advantages of using VFFS machines?
VFFS machines offer an efficient and cost-effective packaging solution with the following benefits:
Automated Efficiency: Speeds up production by automating forming, filling, and sealing while reducing labor costs.
Cost Savings: Optimizes material usage, lowers packaging expenses, and minimizes waste.
Versatility: Handles various bag styles and film types, making it suitable for powders, liquids, solids, and granules.
Reliable Sealing: Ensures product freshness and prevents contamination with precise heat or ultrasonic sealing technology.
Compact & User-Friendly: Saves space with a small footprint and features intuitive controls for quick changeovers.
Enhanced Features: Integrates with weighers, fillers, date coding, perforation, and resealable zippers for added functionality.
Unified Flex provides tailored VFFS solutions to enhance packaging efficiency and product quality. Contact us today to explore how we can optimize your packaging process!
Can vertical bagger machines/VFFS machines/ Vertical form fill seal machines handle different bag sizes?
Vertical Form Fill Seal (VFFS) machines are designed to handle a variety of bag sizes, accommodating different packaging requirements. The specific bag dimensions vary by model.
Here are some examples of Unified Flex’s VFFS machines and their bag size capabilities:
Auto Pouch Bagger AP-140: Designed for smaller bag sizes, it can produce bags up to 4.5 inches in width and 7.5 inches in length.
VFFS Vertobagger Hornet: Handles bags up to 13 inches wide and 20 inches long.
VFFS Vertobagger Maverick: Suitable for bags up to 10 inches in width and 12 inches in length.
VFFS Vertobagger Hornet XL: Produces bags up to 18 inches in width and 30 inches in length.
Adjusting the bag size typically involves changing the forming tube and making machine setting adjustments to match the desired bag dimensions. This flexibility allows manufacturers to package products in various quantities and sizes efficiently.
For detailed specifications and to determine the best machine for your specific bag size requirements, contact us.
What Role Does a VFFS Machine Play in Modern Packaging?
A vffs machine plays a vital role in modern packaging by helping brands meet today’s demands for speed, flexibility, and shelf appeal. At Unified Flex, our VFFS machines are built to handle a variety of products, from powders and granules to IQF foods, while producing different bag styles. This allows manufacturers to adapt quickly to market changes, reduce packaging waste, and deliver consistent, retail-ready packaging that protects product quality and boosts operational efficiency.
What are the core components of a vertical form fill and seal machine and their functions?
Unified Flex vertical form fill and seal machine features key components, including a film unwinding system, a forming tube and shoulder for bag shaping, precision filling systems, and advanced sealing jaws. These components work seamlessly to create consistent, high-quality packages while minimizing waste and downtime.
How do you evaluate vertical form fill seal machine manufacturers when selecting a supplier?
When choosing vertical form fill seal machine manufacturers, focus on proven performance, customization, and dependable support. Unified Flex stands out by offering tailor-made VFFS machines designed to meet your specific product and packaging needs, backed by expert engineering, comprehensive training, and dedicated after-sales service to ensure long-term success.
What key factors should you consider before purchasing a VFFS packaging machine?
Before investing in a VFFS packaging machine, consider your product type, desired bag styles, production speed, and packaging material. Unified Flex offers tailored solutions, ensuring you get a machine designed to meet your exact operational and efficiency goals. For more details, contact us now.
What types of bag styles can a VFFS machine produce?
Unified Flex VFFS machines can produce a wide range of bag styles, including pillow bags, gusseted bags, stick packs, and more. This versatility helps brands deliver attractive, functional packaging that meets both retail and bulk packaging needs.
Which packaging materials and features can be used with a vertical form fill seal packaging machine?
Unified Flex VFFS machines work with a variety of high-performance packaging materials designed to protect product quality and extend shelf life. These include high-barrier laminations, which prevent moisture, oxygen, and light from compromising freshness, ideal for foods, powders, and pharmaceuticals. Metalized films such as BoPET or BOPP offer added strength and protection, while OPP laminations provide clarity, durability, and cost efficiency. Our machines also support features like resealable zippers, easy-open options, and Modified Atmosphere Packaging (MAP) to deliver durable, user-friendly packaging solutions.