Flow Pack: the ultimate guide with applications and 8 advantages

Flow Packaging Systems (HFFS) are becoming one of the most widely used packaging methods.

In fact, they have become increasingly popular in recent for packing all kinds of products, from food to everyday items.

According to the Future Market Insight (FMI) the global market for the industry grew by 2.9 percent during 2015-2021. Based on the outlook it will reach $6.8 billion by 2032, up from $4.8 billion in 2022.

In particular, Flow Pack packaging machines fall under single-serving packaging. Single-serving sachets are particularly popular because they can preserve products for a vast amount of time.

But what is Flow Pack specifically? What are the advantages of Flow Packs?

In this guide we will analyze and explain in detail:

• Operation
• Materials
• Production speed
• Applications
• Advantages
• Videos

of our Flow Pack packaging machines

Operation

Flow Pack packaging machines get their name from their packaging technique.

The materials to be packaged, in fact, are aligned and 'flow' one by one on a belt to be heat-sealed by a film: the products are wrapped entirely in a plastic film (standard or recyclable) and finally closed by a sealing bar.

The kind of bag we get will be similar to the one produced by a vertical packaging system (VFFS).

This packing system involves a mass-production in which rollers and reels move, fill, seal, and cut sheets of plastic material.

Four tasks are performed in one continuous operation.

The pouch can be closed in different ways: with or without weldings, with or without modified atmosphere injection (MAP).

The MAP packaging allows to extend the shelf-life of the product, protecting it from dust and atmospheric agents that could compromise its integrity and quality.

Packing rates are quite high. As well as being very secure, the packaging is also aesthetically pleasing, making it the ideal solution for off-shelf products.

Flow pack wrappers (HFFS) represent an increasingly popular choice for their speed and precision.

Flow Pack horizontal packaging

Flow Pack packaging is part of the horizontal packaging.

The pouch thus obtained will have the shape of a pillow.

A tab may be present close to the longitudinal weld. Each package requires the creation of three seals and a fold.

The horizontal flow pack packaging machine is recommended for medium-large productions.

Materials

Different types of film can be utilized. Thick or thin, compostable or recyclable. Particularly, polypropylene and  polyethylene.

• polyethylene terephthalate (PET) - a thermoplastic resin of the polyester family, often used for liquid and food containers.
• polyethylene (PE) - The most common plastic in use today. With several uses including plastic packaging.

This is especially popular because it is lightweight, nontoxic and extremely durable.

Production speed

The speed of flow packing varies depending on various factors including machine type and package size: average speed of packaging from 40 to 60 pieces/minute.

Applications

The Flow Pack packaging is used in various sectors. Its versatility makes it an ideal solution and extremely popular in many area sas:

• food sector for snacks, chocolate bars, baked goods, meats and cold cuts, dried fruits, cereals and much more

• pharmaceutical and cosmetics sector for masks, lotions, creams and general body care products.
• industrial sector for small electronic and mechanical parts.
• miscellaneous, small items

In particular, it is used in the food industry and in the packaging of typical products such as snacks, bars, baked goods, nuts, chocolate, and many other food products. For example, over-the-counter mini flow packs are very common.

Advantages

The advantages of Flow Packs over other packaging methods are:

• Versatility - This is expressed in different areas and contexts. As much practically as aesthetically, without neglecting the economic aspect, the sustainability issue and that relating to format.
• Production speed - Flow Pack packaging machines ensure high efficiency and high production speed, reduction of packing time and automation of the packaging process.
• Packaging security - Perfectly sealed, it provides a barrier function due to its high insulation and protection, therefore protecting the product from external contamination. Its easily cleaned and sanitized stainless steel structure is capable of meeting appropriate hygiene and safety standards.
• Adaptability and flexibility – There are several types of suitable products.
• Resistence - The use of polyethylene and polypropylene film ensures flexibility and strength.
• Significant economical savings - Flow Pack packaging requires the use of less energy than more traditional packaging tools and less packaging materials. They have excellent value for money.
• Attention to sustainability and lower environmental impact - Key theme from the perspective of growth and development. It concerns the possibility of using disposable, recyclable materials and generating less waste. A sustainable solution in line with customer requirements and sensitivities. They help decrease the environmental impact of packaging, compared to more traditional systems such as rigid, plastic or cardboard cases.
• Customizing - Possibility of using any graphic element on the film that wraps the product. Guaranteeing not only quality but also aesthetics. Customization of packaging as well, with the possibility of using single-serving versions or other modalities.

It therefore represents one of the most reliable and versatile packaging options of the moment.

Trust our experience and know-how.

Request a free quote. Our team and experts are at your complete disposal. 

Videos

Below is a practical video demonstration of our Flow Pack in action.