Application Technique

Vertical Form Fill and Seal

Catalog Numbers ControlLogix, CompactLogix, Integrated Motion on the EtherNet/IP Network

The Vertical Form Fill & Seal (VFFS) application is a way of packaging that
vertically forms a tube (pouch), fills the pouch with product, and then seals the
pouch. These types of applications are usually in the primary packaging area of a
packaging line, where machines take finished products and put them in a
package.

Vertical Form, Fill, and Seal (VFFS) machines are used in the consumer products
industry for a wide variety of packaging applications. Various products like salt,
tea, sugar, spices, snack foods, wafers, detergent, and candies are placed into
formed pouches and then sealed. The pouch material is flexible and typically
heat-sealable plastic. Paper is also used and sealed by glue.

Some systems include vertical-form-fill-and-seal baggers, computer combination

weighers, and bag-in-box systems. A bagger is a high-speed continuous motion
system for poly or supported films, which forms a wide variety of bag styles,
ideally suited for USDA applications.

For more information see the following Rockwell Automation websites.

• http://ab.rockwellautomation.com/Motion-Control/Kinetix-5500-Servo-
Drive
• http://ab.rockwellautomation.com/Motion-Control
2 Integrated Motion Applications: Vertical Form Fill and Seal

The Rockwell Automation Integrated Architecture™ with Integrated Motion on

the EtherNet/IP network is ideal for VFFS machines.
Weight Sensor Feeder PanelView™
Edge Detection Terminal
Proximity Switch

Forming Tube
Proximity Switch
End of Roll

CompactLogix™ System

Kinetix® 5500 Drive

and a VPL Motor
Film Pull
Belts
Kinetix® 5500 Drive Cross (sealing) Jaw
and a VPL Motor
Back-up Detection Photoeye Sensor

A servo axis on the roll of film is used to maintain tension in the process, so the
exact amount of film material can be used with minimal waste. This servo axis
feeds the correct length of film into the formed film tube. If the film is
pre-printed, a registration sensor adjusts the film position to maintain the correct
print position. As the feed servo axis pulls the film down, the goods to be
packaged are gravity-fed into the tube, often by a precision scale, which ensures
that the proper amount of goods are placed in the pouch. Before product is put
into the pouch, the cross jaw servo axis seals the bottom of the pouch, then it is
filled and the cross jaw seals and cuts the pouch.

Built-in PID functionality provides accurate control of the film unwind

mechanism by controlling such devices as unwind brakes or motors, as well as
accurate temperature control of a variety of devices. Native math capabilities in
the Logix processor provide a powerful environment for creating complex
algorithms.

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 Integrated Motion Applications: Vertical Form Fill and Seal 3

Registration inputs to the Logix processor are able to record not only the position
of any physical axes independent of the process, but also the time the input
occurred. This time can be used to determine precise positions for all other
physical and virtual axes in the system to help control accurate film positioning.
Pending cams on an otherwise continuously recurring cam motion bring the
bagging hands to a stop and restart them within half a product cycle to control
dwelling when product is unavailable. Plant-floor operators can select
appropriately-sized cam profiles by entering parameters from the operator
terminal, or calculate profiles on the fly with the MCCP instructions.

Intermittent and Continuous VFFS machines can be intermittent or continuous motion. Intermittent motion
machines operate on the principle that vertical bag seals are made when the film is
VFFS Applications moving and horizontal seals occur when the film stops. Intermittent motion
machines offer a suitable solution for applications where speed is not absolutely
paramount.

An intermittent motion machine is used for washdown applications, such as

poultry or seafood. These machines can weigh everything from dry flowables,
such as seasonings and snacks, to large, irregularly shaped semi-moist foods, like
fresh-poultry parts. A machine can have variable speeds, depending on the
volume and product characteristics.

Continuous motion machines operate on the principle that both vertical and
horizontal bag seals are made when the film is in motion. These machines operate
at the highest attainable speeds and require a reciprocating sealing-jaw motion
format.

There are two major process advantages for a continuous motion machine over
an intermittent type:
• Faster cycles times. On a continuous motion machine, the cross jaw moves
with the film and can perform the horizontal sealing application while the
film is still moving. The typical intermittent machine operates at 60…80
packs per minute (ppm) maximum, while a continuous machine can
operate up to speeds of 180 ppm. The highest machine speed attainable is
determined by the weighing mechanism.
• Control over the cross jaw along the vertical plane provides additional bag
making possibilities.

For instance, for a basic intermittent VFFS machine there will be some sort of
timing axis or PLS channel to coordinate the dosing section with the bag making
process, for example multi-head scale, auger, or volumetric cup filler.

The film pull belt axis is indexed at either specific lengths and then stopped, or at
calculated stop distances, which are based on control variables and machine
dynamics, and then stopped on the registration mark.

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Once the film pull belts have stopped, the cross jaw can commence the sealing
process. The Film Unwind control is handled as a separate function based on
dancer position and whether or not the film is in motion. Vertical and horizontal
bag seals are made when the film is in motion.

Fully automatic VFFS machines require limited operator intervention. The

operator need only replenish product by loading supply hoppers or changing
packaging film drums. For machines that are semi-automatic, operators are
required to perform part of the packaging operation.

The VFFS machine can be divided into four functional areas:

• Mixing, weighing, and dosing
• Forming
• Feeding, aligning, and registration
• Closing, sealing, cutting
Typically, roll-fed flexible packaging film is unwound from a feeder roll. A dancer
roll maintains a constant tension on the unwinding web of film. The unwinding
motor and dancers are required for maintaining tension and critical accuracy in
feed.
The film is threaded up over a forming collar and then down, forming the web
into a chute-like tube. For perishable food products, gas flushing is executed to
prolong the shelf life. The process involves injecting an inert gas, like carbon
monoxide, into the package cavity before it is sealed. A vertical overlap seam and
bottom seal are applied. The pouch is then filled and a top seal applied while a
knife cuts the sealed pouch from the descending web of film.
A VFFS application can consist of the following:

Hardware
• Feeding system
• Film unwind
• Analog dancer
• Film registration
• Registration sensor
• Forming tube
• Film pull belts
• Cross jaws

Software
• PID control
• Discrete control
• Servo
• VFD
• Servo control
• Registration correction code
• Electronic camming

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 Integrated Motion Applications: Vertical Form Fill and Seal 5

Bagger
If a machine packs milk powder bags in a continuous manner, while the bagger
pulls film from roll stock and forms it into a tube, continuous motion sealing
tools apply heat to the seal areas to form the vertical seal and the cross seal of the
bag. Each time a cross seal for a new bag is made, the bagger calls for a charge of
product from the feeder. As soon as the correct amount of product is dispensed,
the filled bag is advanced to receive a top seal. As the top seal is made, the finished
bag gets cut off from the next bag to be filled.

Servo Drives

Servo drives are used for the product-metering pump, and they are used as linear
actuators to control the filling cycle. The servo motor is used to control the main
injector, and manages the speed and acceleration of the bag-making process. To
help lower costs, a metering system can be used to focus on additional product
precision for reduced waste. In addition, servo metering assists in reconfiguring
the machine very quickly, helping to save time and increase throughput.

The machine must manage the measurement and insertion of product into the
pouch, which requires tight coordination with the scales, augers, and mixers:
• For perishable product, the machine needs to be washed down for sanitary
purposes.
• For food products, gas flushing with inert gas or O2 extraction is required
to extend food shelf life.

Film Unwind

In the film unwind section, packaging material is unwound into the machine.
When designing your system, consider material splice, roll change out, and film
tension. Depending on required machine performance, you will use a stepper,
servo, DC gear motor, or VFD.

Film unwind is responsible for unwinding film into the machine, providing
operator ease-of-splice (optional), roll change-out features (optional), and film
tension. Many unwind sections are static mandrel (un-powered) types and use
either a pneumatic brake or friction brake to control unwind action and provide
applicable film tension. Although, occasionally the unwind mandrel will require
VFD, Servo, or DC gear motor type control.

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In the unwind section, often there are roll change features, such as dual mandrels,
roll lifts, and vacuum splice bars. A vacuum splice bar is a horizontal bar with a
vacuum manifold built in and a small horizontal slot (suitable to accommodate a
utility knife blade) through the middle of the bar. The unwind section includes
the film tension and/or dancer. The dancer can provide a speed feedback (analog
or discrete) to the unwind control circuit, as well as a film accumulator area for
bag index purposes, especially on an intermittent type machine. Additional
options possible for the unwind section are functions like zipper applicators and
breather inserters.

Sensors

These are the types of sensors you can use in an application:

• A diffuse sensor to detect the end of a film roll
• An Inductive sensor to detect the over and under travel of a tension arm
and checking for a missing lug
• A registration sensor to detect registration marks that synchronize the
sealing and cutting operations
• An optical torque sensor to detect an edge for centering a trim
• A retro-reflective photo eye to jams at the outlet

Film Registration

The registration mark with a

registration sensor is used as
a method to make minor
adjustments to the actual
end placement of the seal
and cut on a bag. The film
registration sensor, film
alignment, and tracking
adjustment mechanisms
must be considered.

This section includes the film registration sensor and placement adjustment
mechanisms. The film registration is used on film with graphics or pre-printed
information. Printing process variations, film stretch, film slippage during
acceleration, and other factors can allow the graphics to drift away from ideal
cosmetic/marketing placement on the finished bag. The registration mark
provides a method to make minor adjustments to the actual end placement of the
seal and cut on a bag. When there is no printing or graphics on the bag, the
process is defined solely on length. Also located in the film registration section, it
is common to have the film alignment/tracking adjustment mechanisms. These
are used to make sure that the film stays in the correct place on the forming tube.

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Forming Tube
Flat film is converted into a tubular or tunnel
shape. The film travels on the outside of the
forming tube. The cone and correct diameter
tube are combined to form the flat film into a
tubular or tunnel-type shape.

You can use unique mechanical designs for

different machines , for example, films and
products being sealed - inverted cone with
radius corners. You would use PID loop to
control the heating elements of the static bar via
the main controller or separate standalone PID
controllers.

The forming tube mechanics are often unique designs for different machines,
films, and products. However, the general description is an inverted cone with
radius corners. This cone and the correct diameter tube (shapes can differ from
round for special package needs) are combined to form the flat film into a tubular
or tunnel-type shape, which ends up being wrapped around the external surface
of the actual forming tube. To provide extra film for the long or ‘back’ seal, the
width of the film must be greater than the circumference of the forming tube.
The long seal is formed by several heater mechanical configurations that are
typically placed on the front of the forming tube and are 8…12 in. long. Linear
film speed and type are factors in determining the correct minimum length of the
long seal. There are two main types of long seal.

The first type of long seal is the static bar, which is a heated bar with a heating
element and thermocouple. This bar is engaged into the film and forming tube
only while the film is in motion, with slight timing delays to prohibit melting of
the film when stationary. There can also be two bars, but placed where they are
facing one another in a manner to allow the long seal flaps to be placed in
between the two bars. This method is used instead of the overlapping method
used for single bar configurations. This can provide stronger seals/seams and the
product ambient temperature (that is, forming tube temperature) has less of a
factor on the loop control.

The second type of long seal is the dynamic belt, which is a single-heated stainless
steel belt with two pulleys. A heated plate transfers the heat to the stainless steel
band or belt and is engaged into the film and forming tube while the film is in
motion. Like the static bar type, there can also be dual dynamic belts/bands. The
benefit of dynamic belts is that they can move with the film and also be adjusted
to operate faster than the base film speed or even slower. These are process
decisions made based on many product, machine, and material factors.

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Film Pull Belts

The film pull belts provide the actual force to pull
the film through the machine and are used to
maintain good film tension on the forming ‘plow’
and tube.

You can use a vacuum belt type for better gripping

control in dusty, high moisture, or cold operating
environments. Use discrete control, servo, VFD, and
registration code.

There are typically two film pull belts—right side and left side. They are typically
vacuum belts, which allows for better gripping. The belt mechanics are often
powered by VFD motors with encoder feedback, servo axes, or perhaps stepper
motors. Occasionally, there is only one motor that is mechanically transferred to
the separate belts, but the general practice is to eliminate the additional special
mechanical costs in lieu of the additional, but more flexible, controls cost. The
film pull belts provide the actual force to pull the film through the machine and
are used to maintain good film tension on the forming plow and tube. Often
code is used to monitor position and velocity error to be sure that slight
mechanical differences are not allowing one side to pull more than the other.

Rotary Jaw
The first type of continuous bagger is the rotary ‘D’ jaw. For a rotary type bagger,
the horizontal plane motion for the front and back cross jaws is replaced with a
rotary type motion. This is accomplished with special mechanisms, orbital
gearboxes, and/or four-bar type linkages. In general, each jaw is attached between
two gears. Each jaw end gear is actuated by a driving gear. Along with some
orientation linkages, these jaws operate in a mirrored fashion so the jaws
maintain the same distance to the vertical plane as they rotate in a top-to-bottom
and around fashion. The main benefit of a continuous type bagger over the
intermittent is that as the cross jaw is now moving along the vertical plane as well
as the horizontal plane, the sealing process can occur without stopping the film
completely.

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Vertical Jaw
The second type of continuous bagger is the box or
square jaw type. This differs from the rotary jaw in that
there are now two mechanical movers for the overall
cross jaw—one is the horizontal-only plane and the
other is for the vertical-only plane.

Although this adds increased controls and mechanical

costs, it can also provide additional bag making process
options, longer bags with fewer constraints, and more
control for product sweeping type functions.
Mechanically, the cross jaw mechanics and motor are
contained on a carriage. This carriage is controlled and
moved along the vertical plane via the vertical mechanics and motor.

The speed of the VFFS machine is the rate at which it is able to the following.

1. Form the bag (pouch).

2. Fill the bag with product.
3. Seal the bag.
4. Cut the bag.
5. Transfer the package for shipment or further end-of-line packaging, such
as a case packer or over wrapper.

The speed of the machine is one of the main attributes in many end users’ buying
criteria. Machine builders design their machines to operate at the highest speed
possible.

Cross (sealing) Jaw

The cross jaw seals the top of filled

bag and creates a bottom seal of next
bag. It then cuts and separates these
two bags. When designing, keep in
mind whether to use an intermittent
or a continuous feeding line in
relation to the complexity of the
sealing jaw. You will be using discrete control, servo, VFD, PID, and electronic
Camming.

The cross jaw is responsible for three major functions—to seal the top of the
previously filled bag, to create the bottom seal for the soon-to-be-filled bag, and
to cut or separate the completed bag from the bottom of the new bag.

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10 Integrated Motion Applications: Vertical Form Fill and Seal

The front and back cross jaws operate as a pair. The front and back jaw both have
a top seal area (horizontally) and a bottom seal area. Additionally, either the front
(typically due to maintenance reasons) or the back jaw set has a knife that runs
horizontally in the middle of the jaw face. This knife is recessed and is activated
by a pneumatic actuator. The opposite jaw set contains the anvil for the knife.

Each jaw has have one or two heating elements and a thermocouple for
temperature control. Additionally, the cross jaw section can have options like
product wipers, bag deflators, bag hanger punch, gusset (single and double)
creation mechanics, and flat bottom bag mechanics.

Cross jaws are typically configured mechanically, where the front and back jaws
interpose each other and therefore meet in the vertical center-line of the bag and
forming tunnel. However, there are also versions where either the front or back
jaw is stationary and the opposite jaw is moveable. Servo drive/motor
combinations, VFD drives with induction motors, and high-power pneumatic
cylinder actuators are used to close the jaws and provide the necessary sealing
pressure to provide a suitable bag seal.

It is very common for the jaws to contain built-in springs to allow for some
closure error as well as a default force. Often, position and torque data are
monitored for the cross jaws. This data can be used to detect product in the seal
or between the jaws. Any time there is product in the seal, these two bags must be
discarded due to potential seal/seam leakage.

The previous sections are typical for an intermittent VFFS machine; however, a
continuous machine contains a section called the rotary or vertical jaw,
depending on the bagger type.

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 Integrated Motion Applications: Vertical Form Fill and Seal 11

VFFS Machine Formats The type of products to be packaged influences the type of application schematic
required for the machine sections. Product characteristics, such as size,
consistency, and weight, are important details that influence the control system
application modules. Product mis-feeds can lead to product jams in the sealing
section, for example. Suitable jam detection sensors are required to detect this
early.

There are three types of VFFS machine formats.

Single Lane
A single lane tube is formed to the shape of the pouch during each cycle. This
format is suitable for many pouch sizes. This is the most common VFFS
configuration.

Multi Lane

A multiple lane of tube is used to form multiple pouches during each cycle. This
type is mostly used for small packets, such as sugar and salt.

Exposed/Open and Closed Machines

An exposed machine that is closed is sealed so that it is not exposed to the

washdown.

An exposed machine that is open is completely made of stainless steel.

Machine Speed

Challenges in designing machines for speed include the following.

• How to design the mechanics of the machine to operate at a high speed

and maintain the correct tension of the film feed in order to maintain the
quality of the packaging.

• How to position the film accurately based on eye mark registration.

• How to design the optimum sequence of machine operation.

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12 Integrated Motion Applications: Vertical Form Fill and Seal

This is an example of a example of a Form, Fill, and Seal operation intermittent

duty cycle timing diagram.

Packaged Product Types The type of a product influences the application design. The following are the
packaged product types in a VFFS application.

Product Type Example Machine Function Application Needs

Liquid Sauces and shampoos Dosing The machine must manage the
measurement and insertion of
Fine granules Sugar and salt Dosing, mixing product into the pouch, which
requires tight coordination with
Coarse granules Cereals and spices Dosing, mixing the scales, augers, and mixers.
Powders Detergent Dosing, mixing For perishable products, the
machines need to be washed
Solids Candy, pharmaceuticals, Weighing down for sanitary purposes.
and hardware For food products, gas flushing
Fresh produce Vegetables Dosing, gas flushing for with inert gas or O2 extraction is
product protection, and required to extend food shelf
wash down life.

Perishables Meat and fish Dosing, gas flushing for

product protection, and
wash down

Packaging Materials

Packaging material selection is based on the type of products packaged. Plastics

and paper based films are widely used in most packaging machines. The
packaging material used can generate unique application requirements.

For instance, high static charges are generated when plastic packaging film is fed
from a wind-off roll. The static charge attracts powder and lightweight dust from
the filling product onto the internal film surface, thus preventing effective
sealing. A static eliminator bar or contaminant spray can be used to reduce this
problem. Film tension must be maintained.

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 Integrated Motion Applications: Vertical Form Fill and Seal 13

Sealing and cutting jaws must take action after the product is received,
completing the process of bag formation. There may be multiple designs for these
components but there is one general requirement—film velocity and jaw sealer
velocity must be identical. Any disturbance in timing can damage the bag and
waste both packaging and product.

Your choice in package materials is based on what type of products you need to
package. The most common packaging materials are plastics and paper based
films.

Material Type Application Needs

Plastic Film tensions must be maintained. Sealing and cutting jaws must take action
after the product received, completing the bag formation process.
Plastics performed There can be multiple designs for these components but there is one general
Plastics multilane requirement. The film velocity and jaw sealer velocity must be identical. Any
disturbance in timing can damage the bag and waste both packaging and
Paper product.
Composites

Rockwell Automation Publication MOTION-AT002A-EN-P - December 2012

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