Sachets are typically packed, meaning filled and formed, using a specialized automated process called Vertical Form Fill Seal (VFFS).
Understanding Vertical Form Fill Seal (VFFS) for Sachets
Based on industry practices, sachets are filled using a method called vertical form fill seal (VFFS). This process is carried out using a vertical form fill seal machine. This efficient method begins with a flat roll of film. The machine then takes this film and forms it into individual sachets, simultaneously filling them with the product. Crucially, the sachets will be formed as the product is filled.
This automated approach is highly efficient for producing large quantities of single-serve sachets quickly and consistently.
The Sachet Packing Process Using VFFS
While the exact mechanics can vary between machine models, the core steps in packing (forming and filling) a sachet using VFFS are:
- Film Unwinding and Forming: The flat roll of film is unwound and guided through a forming collar or tube. This collar shapes the flat film into a vertical tube with the edges overlapping.
- Vertical Sealing: A sealing mechanism seals the overlapping edges of the film tube together, creating the back seam of the sachet.
- Horizontal Sealing (Bottom): Horizontal sealing jaws come together to seal the bottom of what will be the first sachet (and the top of the previous sachet).
- Filling: The product (liquid, powder, granules, etc.) is dispensed through the center of the vertical tube, dropping into the newly formed pouch segment below the horizontal seal. As highlighted, the sachets are formed as the product is filled.
- Horizontal Sealing (Top) and Cutting: Once the product is filled, another set of horizontal jaws seals the top of the filled sachet. A cutting mechanism then separates the finished sachet from the film tube, ready for the next sachet to be formed below.
This continuous motion allows for rapid production rates, essential for high-volume sachet packaging.
Why VFFS is Standard for Sachets
VFFS technology is the standard for sachet packing due to several advantages:
- Efficiency: High speed and continuous operation.
- Cost-Effectiveness: Reduces labor costs compared to manual packing.
- Versatility: Can handle various film types and products (liquids, powders, solids).
- Consistency: Produces uniformly sized and sealed sachets.
This automated method ensures that sachets are not only filled accurately but also securely sealed and consistently formed from the initial film material.
| Process Step | Description | Output |
|---|---|---|
| Film Forming | Flat film rolled into a tube with overlapping edges | Continuous film tube |
| Vertical Sealing | Overlapping edges sealed | Film tube with a back seam |
| Horizontal Sealing | Bottom of current sachet (and top of previous) sealed | Pouch bottom formed |
| Product Filling | Product dispensed into the pouch (as it's forming) | Pouch segment filled with product |
| Horizontal Sealing | Top of current sachet sealed | Sealed, filled pouch |
| Cutting | Sachet separated from the continuous film tube | Individual, finished sachet |
In essence, packing a sachet relies heavily on the integrated forming, filling, and sealing capabilities of a VFFS machine operating from a roll of packaging film.
