What Are the Advantages of Horizontal Packaging Machine？

Packaging machines are essential in manufacturing and distribution, with horizontal and vertical packaging machines serving distinct roles. Horizontal machines are versatile, handling a wide range of solid, irregularly-shaped, or fragile items across industries like food processing, cosmetics, and pharmaceuticals, often at higher speeds.

Vertical machines excel in packaging powders, granules, and liquids efficiently in a space-saving design, making them ideal for food, beverage, and chemical sectors. Understanding the differences in applications, speed, product compatibility, and space requirements is crucial for selecting the right machine for specific packaging needs.

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Horizontal Flow Wrap Basics

Horizontal packaging machines, also known as horizontal flow wrap machines, are automated systems designed for packaging a wide variety of solid products in a horizontal orientation. These machines are particularly well-suited for single solid goods that can be easily handled, such as cereal bars, soaps, small toys, and bakery products.

Key Features

Feature Description Packaging Process Forms, fills, and seals packages horizontally Product Compatibility Ideal for solid, irregularly-shaped, or fragile items Efficiency Offers high speed and efficiency, especially for consistent product shapes Sealing Capable of creating hermetic seals, ensuring product freshness and integrity Versatility Can be equipped with various options like robot counting, feed systems, and cartooning machines Industry Applications Suitable for food, chemical, cosmetics, and pharmaceutical sectors

Horizontal packaging machines utilize a continuous Packaging Process, making them highly efficient for high-volume production. They can be customized with various features to meet specific packaging requirements across different industries. These machines excel in precise product presentation, ensuring a professional and polished look for packaged items.

One of the key advantages of horizontal packaging machines is their ability to handle a wide range of product sizes and shapes. This versatility makes them an ideal choice for businesses that need to package diverse product lines. Additionally, horizontal packaging machines often achieve higher speeds compared to vertical machines for certain products, particularly those with consistent shapes that can be easily counted and filled.

However, horizontal packaging machines may have limitations when it comes to packaging powders, granules, or liquids, which are better suited for vertical packaging machines. They also typically require more floor space compared to vertical machines, which can be a consideration for facilities with limited space.

Vertical Packaging Explained

Vertical packaging machines, also known as vertical form fill seal (VFFS) machines, are automated systems designed to package a wide variety of products in a vertical orientation. These machines are particularly well-suited for powdery, granular, or liquid products that need to be packaged in a stable and leak-proof manner.

Key Features

Feature Description Packaging Process Forms, fills, and seals packages vertically Product Compatibility Ideal for powders, granules, liquids, and some solid items Efficiency Offers high-speed packaging, typically up to 100 bags per minute Space Efficiency Compact design, requires less floor space than horizontal machines Versatility Can handle various bag styles and materials Industry Applications Suitable for food, beverage, pharmaceutical, and chemical sectors

Vertical packaging machines operate by forming a tube from a flat roll of film, filling it with product, and then sealing and cutting the tube to create individual packages. This process occurs simultaneously, allowing for efficient and continuous packaging operations. The machines can work with a variety of packaging materials, including plastic, metalized foil/film, paper, and fabric.

One of the key advantages of vertical packaging machines is their ability to handle a wide range of products. They are particularly effective for items that need to be dropped into packages, such as coffee, sugar, powdered milk, flour, rice, and beans. The vertical orientation allows for gravity-assisted filling, which can be beneficial for certain product types.

Vertical packaging machines often come equipped with various feeding systems to accommodate different product requirements. These can include liquid pumps, volumetric fillers, and multi-head weighers, allowing for precise filling by weight, volume, or individual units. This flexibility makes them suitable for a diverse range of packaging applications.

Another significant advantage of vertical packaging machines is their space efficiency. Due to their vertical orientation, they typically require less floor space than horizontal machines, making them an excellent choice for facilities with limited space.

However, vertical packaging machines may not be as fast as horizontal machines for certain products, particularly solid goods. They also may not be suitable for packaging delicate items that could be damaged by dropping during the filling process.

In terms of operation, modern vertical packaging machines often feature user-friendly touch screen controls, allowing for easy adjustment of packaging parameters such as pouch weight and dimensions. This simplifies operation and reduces the need for extensive training.

Overall, vertical packaging machines offer a versatile and efficient solution for packaging a wide range of products, particularly in industries dealing with powders, granules, and liquids. Their compact design, flexibility, and ability to handle various packaging materials make them a popular choice across multiple sectors.

Buying Considerations

When selecting between horizontal and vertical packaging machines, there are several important factors to consider. Here is a comparison of key considerations:

Consideration Horizontal Packaging Machine Vertical Packaging Machine Product Type Best for solid, irregularly shaped items Ideal for powders, granules, liquids Packaging Speed Generally faster, up to 400 bags/min for some products Typically slower, but efficient for certain items Space Requirements Requires more floor space More compact, space-efficient design Product Handling Gentle handling of fragile items Gravity-assisted filling, may not suit delicate products Flexibility Adaptable to various product sizes and shapes Versatile for different bag styles and materials Sealing Quality Can achieve hermetic seals Simultaneous sealing and filling Industry Applications Food, cosmetics, pharmaceuticals, hardware Food, beverages, chemicals, pharmaceuticals Ease of Operation May be more complex Often simpler with user-friendly controls Packaging Materials Limited with some film types Works with a wide range of materials

When choosing between these machines, the product to be packaged is the most critical factor. Vertical machines can generally handle a wider variety of items, while horizontal machines excel at packaging consistent shapes at high speeds. For example, a horizontal machine with a candy feeder can package over 400 bags of hard candy per minute, which a vertical machine cannot match.

Other important considerations include the available floor space in your facility, the desired packaging speed, and the specific requirements of your production line. It’s also crucial to consider the machine’s flexibility and adaptability to potential future changes in your packaging needs.

The ease of operation and maintenance should also be factored in. Many vertical machines offer user-friendly control panels and automatic weighing and filling systems, which can be advantageous for some operations.

Lastly, consider the total cost of ownership, including not just the initial purchase price, but also operating costs, energy efficiency, and maintenance requirements. By carefully evaluating these factors, you can select the packaging machine that best suits your specific production needs and business goals.

Key Takeaways

Horizontal and vertical packaging machines each offer distinct advantages and are suited for different applications. Horizontal machines excel at handling solid, irregularly-shaped items and can achieve higher packaging speeds, making them ideal for industries like food processing, cosmetics, and electronics.

Vertical machines, on the other hand, are better suited for powdery, granular, or liquid products and offer efficient handling of heavy packages in a space-saving design. When choosing between the two, consider factors such as product type, desired packaging speed, available floor space, and specific production needs.

Both machine types can be customized with various features to meet unique packaging requirements across different industries. Ultimately, the decision should be based on a thorough analysis of your business’s specific packaging needs and long-term production goals.

Frequently Asked Questions

What types of products can horizontal packaging machines handle?

Horizontal packaging machines are versatile and can handle a wide range of solid products, including food items like pasta, bakery goods, and candies, as well as non-food items such as toiletries, hardware, and electronic components. They excel at packaging irregularly-shaped or fragile items.

How fast can horizontal packaging machines operate?

Horizontal packaging machines can achieve high production speeds, with some models capable of packaging up to 200 bags per minute. When equipped with specialized feeders, such as for hard candies, speeds can exceed 400 bags per minute.

What are the main advantages of horizontal packaging machines?

Key advantages include high packaging speeds, flexibility in handling various product shapes and sizes, and the ability to provide more surface area for graphics and messaging on packages. They also offer consistent packaging quality and can integrate easily into production lines.

Are there any limitations to horizontal packaging machines?

While versatile, horizontal packaging machines may struggle with certain materials like monolayer straight PE films. They also require more floor space compared to vertical machines and may not be ideal for powdery or liquid products.

What factors should be considered when purchasing a horizontal packaging machine?

1. Advantages of horizontal packaging machines

This is an automated machine that produces a hermetically sealed cooker from the film. It folds to poach, automatically fills the product, and seals it. Wet as well as dry ingredients can be used in this poaching. The packaging process is the last step in the production line.

Many companies prefer to add horizontal packaging to their product range. This is because of its advantages, listed below.

• Helps in a faster and cheaper production process as it covers all stages of production automatically. This makes the entire packaging process faster.
• This is a flexible packaging solution. No problems filling and sealing solids, liquids, or dry products.
• With this type of packaging, more surface area is available for graphics and written messages.
• Protect cargo from damage, dust and moisture. It reliably ensures product hygiene by eliminating hand contact with food and pharmaceuticals.

The machine is equipped with a safety device, which will stop immediately after detecting abnormal air pressure and heater disconnection alarm.

• It improves inventory because it stacks similar products together. This reduces product separation, which can make counting time-consuming.
• The machine is easy to operate, clean, easy to maintain, and user-friendly. With automatic detection function.
• The machine provides consistent pharmaceutical packaging solutions that are relevant for the export of goods.

2. Disadvantages of horizontal packaging machines

Just like any other machine, this one has some limitations that may prevent it from being used. They include:

• Some brands have limited capacity.
• Even automatic horizontal packaging machines require operators. For semi-automated robots, their workload is even greater.
• To be flexible, it must compromise in at least one key area. These areas include performance, speed, price, conversion time/consistency, memory footprint or complexity.

The operation of this machine requires discipline. It requires mechanical and electronic adjustments to establish the centerline required to run a specific product.

3. Vertical Packaging Machine vs Horizontal Packaging Machine – A Final Comparison

The vertical packaging machine and the horizontal packaging machine have more similarities than differences. These can be seen in their operations, the products they package, specifications and considerations when purchasing.

However, there are some differences between the two machines. So, in this thread, I want you to see the final comparison of the two. This will involve design and construction, advantages and limitations.

1) Mechanical Design and Construction

Vertical and horizontal packaging machines operate differently. Horizontal machines take a roll of film and run it over a plough to create the bottom of the gusset. As a result, the film does not have to be pulled through the machine with as much force. On the other hand, a vertically oriented aircraft uses more force than a vertically oriented aircraft. This is because the film roll is unwound in an upward direction.

2) Film Folding

The film of the horizontal machine is folded flat in only two dimensions after moving on the plowing surface of the machine. In addition to this, the film can also run past subsequent sealing stations. This can allow it to be preheated, heated and cooled in a series of indexing cycles.

In a vertical packaging machine, seal production and bagging are carried out simultaneously. Any further preheating, heating and cooling depends on the time in a single cycle. This may result in a less refined look that may not be up to your approval.

3) Product Filling Process

The horizontal machine fills the product through the top into the film while the bag is pulled open. It has a full bottom gusset. When in use, this provides 100% fill capacity. Most horizontal bags are either ⅔ to three-quarters full. With vertical packaging machines, this filling is difficult to achieve. This is because the bag is formed while filling through both sides of the bag. Here the gussets are not fully opened; therefore, the capacity of the bag is not appropriate.

4) The benefits of machines

Because only one person operates the machine, it is not only cheap but also reduces labour costs and speeds up the production process. Both protect the product from damage, contamination, dust, or moisture because the packaging is reliable with less human contact. Inventory has improved as packaged products stick together.

This makes counting easier and less time-consuming. Additionally, these machines are user-friendly, making them easier to use once the orientation is established. Also, they are easy to clean and maintain. Both vertical and horizontal packaging machines have automatic inspection functions.

They can detect if a package is present, open or closed. This reduces bag or material waste. In addition, these packaging machines use safety devices. When they detect any abnormal air pressure, a heater disconnects alarm sounds to notify operators.

For both, the wrappers are consistent. This is very useful for products exported to other countries. In both machines, human contact with the product is minimized during the packaging process. Therefore, environmental pollution and its impact on human health are reduced.

5) Machine limitations

Vertical packaging machines cannot use hard materials such as paper, poly or foil because it uses more force than horizontal packaging counterparts. On the other hand, single-layer linear PE films cannot be run on horizontal packaging machines.

They all have limited production capacity, which may differ from individual machines. Neither machine can operate independently without an operator. Someone has to get it up and running. Some of these machines make compromises in key areas such as speed for flexibility.

Both machines require operational discipline, as most products have their own centerlines to adjust. Failure to do so may result in a loss of efficiency in the packaging process.

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4. Application of Horizontal Packaging Machine

Many businesses rely on these machines to package products in both solid and liquid form. These applications include:

1) Food processing industry

The company produces egg dry-fried standard dry and stuffed pasta packaged using this application. Bakeries use it to package bread, cakes, pizza, breadsticks, cookies and crumbs. It is used to package beverages such as milk, water, alcoholic and non-alcoholic beverages.

This machine provides reliable standard bags with all aspects of sealing. This method is also used in the packaging of candy, chewing gum, toffee and bubble gum. It is also used to package wet and dry pet food and dental.

2) Cosmetics industry

Wipes to clean cosmetics, babies, refreshing and cleaning pets use this application.

3) Pharmaceutical Industry

They use it to wrap gauze bandages, syringes, blisters and drops.

4) Agribusiness

The packaging of seeds and chemicals also relies on horizontal packaging machines.

5. Horizontal Packaging Machine Parts

The horizontal packaging machine consists of many parts. These components have functions that enable the device to perform its functions efficiently. They include:

• Feed Link/Infeed Conveyor: This part uses 304 stainless steel powder injection codes to help package products in a safe and hygienic manner.
• Pull Membrane Structure / Membrane Former: Here we have a multi-link membrane to coordinate the pull membrane. It also enables the smooth rolling of the film.
• Encoder: This part of the machine uses a ribbon printer to print the date, logo or any desired text on the packaging. It can position the print more clearly and accurately.
• Smart Touch Screen: This is a colour touch screen that helps to set parameters before the machine can be used.
• Automatic sealing: Rotate the hot air incision before and after packaging to ensure both ends are properly sealed.
• Finished Product Delivery/Product Unloading Area: This is where packaged products are unloaded when they are ready to be packaged into cartons.

6. Working principle of horizontal packaging machine

It has a feed conveyor, a membrane supply assembly called the back stent and a membrane formation zone called the anterior membrane. It also has a bottom seal sometimes called a fin seal, a cutting head, and a discharge area.

The food and non-food products produced during the production process are placed on the infeed conveyor of the flow packer. You can manually or use an automatic feeder solution. The conveyor transports the product to the forming area.

The film is drawn from the film supply assembly to the forming zone. This part forms the film tube around the product and creates a fin seal. Then send it to the cutting head. This cutting head creates an end seal, while the sections it cuts are packed into individual packets adjacent to each other. The sealed package is moved to the unloading area, where it can be boxed. The following illustrates how horizontal packaging is completed.

7. Considerations For Buying Horizontal Packaging Machine

When you want to buy this machine, you have to consider a lot of factors. Let’s see how the following factors affect the choice of machine.

1) Model or brand

There are many models and brands of horizontal packaging machines. Some models use 4 servo motors to enable quick and easy switching and adjustment. In the production process, the loss of films and products is reduced, and the maintenance is convenient.

Servo drives help ensure precise positioning, smooth acceleration and deceleration. This also comes standard with pre-programmed store product settings and stainless steel frame construction. The picture below shows one of the models of horizontal packaging machines.

There are also those that use 5 servo motors to create quick and easy switching and adjustments. Keep in mind that there are also brands that combine the features of horizontal and vertical packers in one advanced new compact packer.

This type of packaging machine is the latest and can be used in many applications. Additionally, the vertical position is ideal for automatic bagging and product loading machines. There are trays and containers in the horizontal position. Some have length detection sensors and operation logic. This can be used to adjust the length of the product at each cycle. This adjustment can make the bag according to the length of the product.

2) Specific Application

The choice of correct horizontal packer will also depend on the task you want it to perform. For example, some machines are more suitable for packaging small products, but cannot effectively package large products.

3) Technical Specifications

Vertical packaging machines come in a variety of styles with different technical specifications. For example, some products have higher power consumption and are only preferable when required by the production level and product type.

4) Type of Horizontal packing machine

Choosing these machines can be tricky because there are so many things to consider. To make the best choice, evaluate technical capabilities, labour requirements, worker safety, and maintainability. Also, look at serviceability, reliability, and the ability to integrate into packaging lines.

In addition, capital cost, floor space and conversion, materials and flexibility of multiple products must be considered. Finally, you must consider energy requirements, the quality of the outer packaging, and the eligibility of food and medicines.

Horizontal packaging machines fall into two categories. They are:

Semi-automatic horizontal packaging machine

This machine can be used to pack multiple products in small batches with variable pack sizes. It is suitable for the packaging of sandwich and non-laminated prefabricated bags. It is suitable for filling and sealing non-free-flowing powder chemicals, pharmaceutical powders, food, beverages, cosmetics and other materials.

For precision, the powder is filled with a PLC-based controller with built-in pulses. Helical rotation pulses are modified and adjustable through a touch screen system for accurate weight compensation.

Automatic horizontal packaging machine

The machine grips a pre-formed bag fills it with the product and seals it. The rate of this process is between 40 and 200 bags per minute. It has a positioned circular layer where the bag is moved intermittently to different positions.

Each station performs a different packaging function. There are usually 6 to 10 sites, but the most common configuration is 8. The automatic bagging machine can be designed as a single row, double row or quad row. So let’s look at these monitoring stations in more detail.

• Package loading

The operator manually loads the preformed bags into the bag holder in front of the automatic bag sealer. A bag feeder then delivers the bags to the machine. This machine has a robot that feeds bags with a vacuum, grabs individual bags, and loads them into the bag grabbing area.

• Bag Complaining

This has a proximity sensor to detect the bag, after which the vacuum bag loader picks up the bag. It then transfers the bag to different grippers that hold the bag as it moves to different positions along with the swivel

• Printing/embossing

If this is required, the machine will go through thermal printers and inkjet printers. Printing allows data and lot numbers to be affixed to the bag.

Opening and inspection of zippers/bags

The bag with the zippered shell is opened by a vacuum suction cup which opens the lower part of the preformed bag. Open the pliers by grasping the top of the bag to open it.

This is inflated by separating the top of the bag opens outwards using a blower. There are two sensors on the bottom of the bag that help detect its presence. If not detected, neither the filling station nor the sealing station is involved in the packaging process. If the bag is detected but not placed correctly, it will not be filled and sealed.

• Bag filling

The product descends into the funnel into the bag using a multi-headed scaly spiral filler. For liquids, the product is pumped into the bag through a nozzle. Filling equipment is responsible for correctly measuring and releasing discrete quantities of dripped products.

• Product settings and other options

At this stop, you have to make sure that the loose contents are sealed before the bottom of the bag. To do this, shake the pre-made bag well. Other options for this station include secondary sealing fluids to provide maximum seal integrity.

• Seal bag, deflate

With two pressure reliefs, the seal is complete before squeezing out the bag’s remaining air. After that, the heat seal is closed on the upper part of the bag. Using heat pressing, the preformed pouches are layered with sealant and then glued together to make a strong seal.

• Cooling and draining

A cooling rod is then passed through the seal, making it firm and flat. The machine then places the finished bag into the container. Then it can be transported to other carton packers.

• Production Capacity

The production capacity of each machine varies from 40-200 units per minute. There are large capacity horizontal packaging machines like those used for cosmetic bags

• Power Consumption

Power consumption varies depending on the type of machine. The phase power consumption of horizontal packaging machines can range between 500W and 1KW. A bath soap bag machine consumes 2 kW.

• Quality compliance

This machine is manufactured under the supervision of experienced professionals using the highest quality components and according to quality standards set internationally. A good horizontal packaging machine should comply with CE, CCC, cGMP, RoHS and ISO standards.

A good machine should provide high performance and reliability. It should also be formed, filled and sealed in a single process. It is safe for the product and the user.

• Technology

The technology to make these machines has evolved to the high-speed performance that can run 24/7. Simple design, convenient operation and maintenance. The technology is widely accepted worldwide because it is accurate at the time of delivery.

• Dimension

This also varies from model to model. For example, there are some that measure mm long x mm wide x mm high. Other sizes are l70 – 420xw140xh80mm and many others.

8. Conclusion

Horizontal packaging machines are very relevant to the safety and reliability of products on the market today. Many foods and non-food production companies have adopted this technology because of its cost-effectiveness.

This also provides maximum protection for their products. It can be used to package a wide variety of products, from small to large packages. Due to growing interest in this application, more efficient machines have been developed to limit human exposure to toxic products.