Stand up for pouches, lay down for packs

Form-Fill-Seal systems automate the packing process of dry, solid and powdered goods, increase throughput, and deliver consistent pack performance.

While the use of horizontal (HFFS) and vertical (VFFS) systems varies depending on the product and application, both are core processes in the supply chain and will be demonstrated in depth at Packaging Innovations & Empack 2026.

Horizontal Form-Fill-Seal (HFFS) and Vertical Form-Fill-Seal (VFFS) machines are essential in modern packaging and vital for high-volume industries such as protein, snacks, confectionery, personal care, and pharmaceuticals.

Both types of Form-Fill-Seal (FFS) system automate the entire packing process by forming the pack, filling it with the product, and then sealing it ready for distribution and retailing.

HFFS excels with solid, rigid, or irregularly shaped items, such as chocolate bars, wet wipes, and medical devices, and works well for flow-wrapped products.

VFFS meanwhile, is best suited to free-flowing or granular items (snacks, coffee, powders, rice) and can form pouches in many different formats.

The depth and breadth of FFS will be on show at Packaging Innovation & Empack 2026, where the materials and the machines will be presented for all those contract packers and manufacturers looking to enhance their production capabilities.

Pack to the future

A100 from AutoPack (V132) is a compact and easy to use VFFS machine that offers a low cost of ownership. A100 can be used semi automatically by hand feeding products into the top or coupled with automatic filling machinery such as weighers, augers and liquid depositors. It has a maximum production speed of 40 packs a minute and can handle packaging that is 60-200mm wide and 50-250mm in length.

Horizontal sachet packing machines can produce sachets with widths ranging from 30-170 mm, achieving speeds of up to 200 sachets per minute. They fill and seal multiple sachet styles, including three- and four-sided sachets, various shapes, Euro-slot sachets, sachets with zippers, and more. Post-pack sachet filling machines integrate with labelling devices and filling systems, as well as post-machine collation and packing systems for enhanced flexibility and functionality.

Speedpack Hybrid is a compact FFS system available from Audion Elektro (W102). The advantage of Speedpack Hybrid lies in the system’s design, which allows for the use of tube film and bags-on-a-roll, eliminating the inconvenience of forming collars, back seaming, and the complex controls associated with traditional FFS systems.

All HFFS and VFFS systems are fed by pre-printed rollstock that goes into the system as a flat web before forming, filling, and sealing.

This could be Alox-Lyte™ from Jindal Films (D108), which is a transparent high barrier BOPP film that is vacuum coated on one side with aluminium oxide. To provide a transparent, high barrier solution to water vapor, oxygen, aromas, and mineral oils.

Roll film from Elite Flexibles (C50) can be used either as a mono web or as a laminate for HFFS or VFFS. They are available in different materials, such as PET, PE, PP, and laminated films, to meet specific packaging requirements. High barrier properties protect products from moisture, oxygen, and other contaminants and makes these films suitable for food and non-food applications suited for FFS, including snacks, chips, confectionery, frozen foods, dry foods, and personal care products.