A flow wrapper is an automated packaging system that surrounds products with a continuous flexible film. The machine forms a longitudinal seal and two end seals to create a closed package.
The completed package is often called a pillow pack because of its shape.
Flow wrappers differ from manual packaging systems because they can operate continuously. This makes the equipment suitable for manufacturers processing high volumes of products.
What Is the Flow Wrapping Process?
A flow wrapping machine uses a continuous roll of flexible film to produce repeatable sealed packs.
1. Products Enter the Machine
Products are carried into the machine by a conveyor or integrated feeding system.
2. The Film Is Formed Around the Product
The packaging film is shaped around each product as it moves through the machine.
3. The Length Seal Is Formed
The film is sealed along its length to create a continuous tube around the product.
4. Cross Sealing and Cutting
End-sealing jaws close the package before cutting it into an individual pack.
5. Finished Product
Once sealed and cut, the finished pack moves out of the machine ready for handling, delivery or sale.
Advantages of Flow Wrapping Machinery
Flow wrapping equipment can help manufacturers improve output and produce consistent packs.
Fast Packaging Output
Automatic systems can package thousands of products per hour, depending on the product and machine specification.
Consistent Packaging Quality
Each product receives the same seal quality and presentation. This can help maintain a uniform brand appearance.
Reduced Labour Costs
Automation reduces the amount of manual handling needed during packaging. Staff can therefore focus on other production tasks.
Product Protection
Flow wrapping helps protect products from dust, moisture, contamination and physical damage during distribution and storage.
Adaptable Product Handling
The equipment can be configured for varied product formats and packaging materials.
What Can Be Packaged Using a Flow Wrapper?
Flow wrapping machinery can be used for many food and non-food products.
Common examples include:
- Individual or grouped biscuits
- Bakery products
- Sweets, chocolate bars and confectionery
- Fresh produce
- Selected frozen products
- Medical devices
- Pharmaceutical goods
- Personal care products
- Household goods
- Small industrial and hardware parts
Flow wrapping is used throughout many industries because it can handle both edible products and manufactured items.
Which Packaging Films Work with Flow Wrappers?
Different film materials can be used according to the packaging requirements.
Frequently used films include:
- BOPP film
- Polyolefin film
- Polyethylene (PE)
- PET film
The correct material will be determined by the product type, storage period, presentation requirements and production setting.
When Is It Time to Use Flow Wrapping Machinery?
Many businesses move to automatic flow wrapping when manual packaging begins to restrict production.
Signs that an upgrade may be needed include:
- Your required packaging output is rising
- Hand wrapping creates a production bottleneck
- Packaging quality varies between operators
- Greater consistency is required
- Manual packaging is becoming more expensive
Automatic packaging can improve productivity while maintaining consistent pack quality.
How Do You Choose a Flow Wrapping Machine?
Machine selection requires an assessment of pack format, output and future demand.
Important features include:
- Packaging speed
- Product size capacity here
- Easy product changeovers
- Photocell registration for printed films
- Integrated date or batch coding
- Compatibility with automatic feeding systems
- Clear operator controls
- Consistent and dependable seals
The correct choice depends on your products, current production volume and future growth plans.
How Do Flow Wrappers Differ from Shrink Wrap Machines?
Flow wrapping and shrink wrapping both involve film, but they form packs in different ways.
Flow wrapping machinery forms film around the product before applying length and end seals.
A shrink wrap machine surrounds the product with shrink film before applying heat to tighten the material.
The choice will depend on the desired pack format, the product and how it will be stored or transported.
Can a Flow Wrapper Integrate with Existing Equipment?
Yes. Flow wrapping machinery can often be integrated with equipment already in use.
The machine can work alongside feeding units, conveyor systems and labelling equipment. This allows manufacturers to raise production capacity without replacing every existing system.
Flow Wrapping Machinery from Kempner
Kempner has supplied packaging machines and materials across the UK for over five decades.
Kempner supplies both horizontal and vertical machines that can be configured for different product types.
Available options include photocell registration, date or batch coding and machine configurations for specific production needs.
Support services include machine installation, commissioning, maintenance and technical assistance. These services can help businesses maintain reliable packaging performance.
Questions About Flow Wrapping Machinery
What Is a Flow Wrapping Machine Used For?
A flow wrapping machine packages individual products in flexible film to form sealed pillow packs. These packs can provide protection during handling, distribution and display.
Is Flow Wrapping Suitable for Food Products?
Yes. Flow wrapping is widely used for many bakery, confectionery, snack and fresh-food applications. It provides secure and hygienic packaging.
Are Flow Wrappers Suitable for Non-Food Items?
Yes, they can. Manufacturers use flow wrapping machinery for medical items, pharmaceuticals, small components, personal care goods and household products.
How Many Products Can a Flow Wrapper Package?
Operating speed depends on the machine and the product being packaged. Many high-performance machines can package thousands of individual items each hour.