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 businesses that need to package large quantities efficiently.
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 machine seals the film lengthways so that it surrounds the product in a tube.
4. End Sealing and Cutting
The machine creates end seals and then separates each pack from the film web.
5. Pack Exit
The sealed package exits the machine and can then be stored, distributed or displayed.
Why Use a Flow Wrapping Machine?
Many manufacturers invest in flow wrapping machinery to increase production efficiency while maintaining packaging quality.
High Production Speeds
Flow wrapping machinery can process thousands of products every hour when the equipment and application allow.
Uniform Seals and Appearance
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.
Common Flow Wrapping Applications
A flow wrapper is suitable for a wide selection of food and manufactured goods.
Common examples include:
- Individual or grouped biscuits
- Bakery products
- Sweets, chocolate bars and confectionery
- Fruit and vegetables
- Frozen foods
- Medical products and devices
- Pharmaceutical products
- Personal care products
- Domestic and consumer products
- Hardware components
Its suitability for food and non-food applications makes flow wrapping a common packaging method in manufacturing.
What Films Can a Flow Wrapping Machine Use?
A flow wrapping machine can use several flexible packaging films depending on the product and application.
Available film options include:
- BOPP film
- Polyolefin packaging film
- Polyethylene (PE) get more info
- PET film
The most suitable film depends on the product, required shelf life, desired presentation and production environment.
Should Your Business Move to Automatic Flow Wrapping?
Companies often adopt flow wrapping machinery when hand packaging can no longer keep pace with demand.
A flow wrapping machine may be suitable if:
- Production volumes continue to increase
- Manual packaging slows the production line
- Pack appearance or seal quality is inconsistent
- Greater consistency is required
- Labour costs are increasing
A suitable flow wrapper can raise output and produce more uniform packaging.
Key Flow Wrapper Features
The correct machine should be chosen according to the product and production requirements.
Useful machine features include:
- Packaging speed
- Product size capacity
- Fast and straightforward changeovers
- Photocell registration for printed films
- Integrated date or batch coding
- Compatibility with automatic feeding systems
- Clear operator controls
- Reliable sealing performance
Machine suitability will be determined by the items being packed, required output and expected business growth.
Flow Wrapping Versus Shrink Wrapping
Although both methods use flexible film, the packaging processes are different.
A flow wrapping machine forms a sealed pillow pack from a continuous roll of film.
Shrink wrapping places film around the item and then uses heat to contract it closely around the outside.
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. Many flow wrapping machines are designed to connect with existing production equipment.
Compatible equipment may include automatic feeders, conveyors and labelling systems. This allows manufacturers to increase packaging output without rebuilding the entire production process.
Kempner Flow Wrapping Systems
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.
Machines can be supplied with printed-film registration, optional coding systems and tailored configurations.
The company offers installation, start-up support, servicing and continued technical help. These services can help businesses support dependable long-term production.
Frequently Asked Questions
What Does a Flow Wrapper Package?
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 biscuits, cakes, sweets, snack products and produce. It provides closed packaging that supports hygienic handling.
Are Flow Wrappers Suitable for Non-Food Items?
Yes. 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?
The production rate varies according to product dimensions and machine specification. Many high-performance machines can package thousands of individual items each hour.