Vertical Bagging is Revolutionizing Food Packaging Across Industries
The principle behind how vertical bagging works may seem straightforward enough – a packing machine creating a bag vertically as it packs the raw material – but the impact this has had on a variety of industries has been profound. So, in this article, we will be examining how this impact has manifested across a range of food and drink sectors, and the potential relevance of vertical bagging to you.
Introduction to Vertical Bagging in Food Packaging
Vertical bagging is also sometimes referred to as “vertical form fill sealing”, or VFFS. It is an automatic packing method whereby bags are formed and packed at the same time, vertically. The process entails flat wound film being turned into plastic bags, and then filled and sealed. As one bag is sealed, the bottom of the next bag is created, which allows for the rapid creation of products.
Whether one refers to it as VFFS packing or just “vertical bagging”, it is a process that brings various benefits; it is efficient, it saves space, and it is highly versatile.
From the food industry’s point of view, another major advantage of VFFS packing is the built-in gas flushing process, which preserves product freshness to boost shelf life. Gas flushing displaces the oxygen in a package with inert gas, such as carbon dioxide, nitrogen, or a combination of the two. This prevents oxidation, thereby maintaining product quality.
Applications in the Snack Food Industry
Vertical bagging is a highly relevant and useful process for the packaging of various snack foods, such as crisps, nuts, and popcorn. It is, after all, a method that is well-suited to getting loose, dry products into portion-controlled, airtight packs, which very much describes many snacks.
The advantages of VFFS packing for the snack food sector include the maintenance of product freshness, ease of portion control, and the scope to create attractive packaging designs.
There are, however, a few industry-specific challenges that need to be accounted for, such as the importance of appropriately handling relatively delicate snacks.
Applications in the Frozen Food Industry
Frozen food is clearly a category of product where product preservation – from the point of manufacture to the supermarket, and then through to the customer’s home – is of critical importance.
Sure enough, the vertical bagging VFFS process delivers a variety of benefits for frozen vegetables, fruits, meals, and more. These encompass extended shelf life, efficient storage, and protection from “freezer burn” – the damage that can occur to frozen food due to dehydration and oxidation, caused by air reaching the food. The airtight sealing created by VFFS packing combats this risk.
For the maintenance of product integrity and the prevention of moisture accumulation, vertical bagging plays a powerful role in the frozen food sector.
Applications in the Coffee and Tea Industry
It is also customary for vertical form fill seal machines to be used for the packaging of ground coffee, whole beans, tea leaves, and tea bags. Such machines form bags from a roll of packaging film, with these open bags then being filled with the given product (such as coffee) and sealed.
Vertical bagging can be integral to efforts to preserve the quality, aroma, and flavour of these popular and especially oxygen-sensitive products, which can also be made available in convenient resealable forms. It can help fulfil specialised packaging requirements, such as for vacuum sealing and nitrogen flushing.
Applications in the Pet Food Industry
Every conscientious pet owner will be anxious to ensure they feed their beloved companion in a safe and responsible way. Many animals, after all, have specialised dietary requirements, although it is imperative to maintain the freshness and quality of all dry pet foods, treats, and similar products.
The use of vertical form fill seal machines allows for these priorities to be catered for. At the same time, it helps to ensure careful and accurate control over portions, while enhancing branding opportunities, given that such machines can print custom branding directly onto the product packaging.
Applications in the Dairy Industry
The satisfaction and health of customers could be greatly imperilled if dairy products that they purchase – such as powdered milk or cheese slices – turn out to be contaminated when opened.
Fortunately, vertical bagging has an excellent track record of consistently maintaining product freshness, while prolonging shelf life and enabling multiple portion options to be easily offered to shoppers. With regard to the latter, a target weight can be stipulated for each bag, and the VFFS machine can be trusted to deliver the “minimum fill” every time.
It isn’t only the packaging process itself that is critically important for dairy products, but also ensuring the use of appropriate packaging materials. Fortunately, the fitting of a foil laminate layer is another key part of the VFFS method, further helping to preserve product flavour.
Applications in the Baking Industry
Products related to baking, too – such as flour, sugar, baking mixes, and pastries – can be preserved in high quality for longer when VFFS packing is used. This maximises customer convenience by enabling them to use such products at whatever time suits them.
Moreover, many different size and finish options are available, including the possibility to have bags printed with full branding. So, the given products could be ready to go on sale directly from the vertical bagging facility. Custom bag shapes and sizes can be offered, although specialist forming tools will inevitably be needed for the fulfilment of the most demanding requests.
Packaging for the baking industry is associated with a variety of challenges, such as the need to manage different product consistencies and packaging sizes. However, as we explain in our guide to vertical form fill seal (vertical bagging) processes, VFFS technology can rise to such challenges.
Don’t underestimate the fundamental role our own vertical bagging services and expertise could play in your brand’s success here at WePack. Contact us now to discover the possibilities.