Making the Leap to Automated Packaging: 5 Factors for Choosing a VFFS or Premade Pouch Machine for Your Coffee Roastery 

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Kristi Anderson-Runge

In the dynamic world of coffee roasting, where precision, flavor, and presentation matter, every decision can have a profound impact on the success of a roastery. As the demand for quality coffee surges, the choice of commercial coffee packaging equipment becomes crucial. And as a result, coffee roasters are increasingly considering the switch to automatic coffee packaging machines to streamline their operations, increase shelf life, and promote consistency in their branded packaging. 

We&#;ve written about factors to consider when selecting a manual or automatic packaging machine, so if you decide to take that leap, your next decision will involve exactly what kind of coffee packaging automation is best for you. There are a number of automated packaging options to choose from, but this article focuses on the two most popular options:

the Vertical Form Fill Seal (VFFS) machine and the Premade Pouch machine.

Let&#;s consider five factors to aid in your decision-making: 

1. Speed and efficiency

2. Product line variety

3. Sanitary considerations

4. Aesthetic appeal

5. Sustainable packaging

Speed and Efficiency

When considering the speed and efficiency of Premade Pouch machines and VFFS machines, it's important to match your roastery's production volume, capacity for skilled labor, and budget with the capabilities of each machine type. 

While Premade Pouch machines offer flexibility and cost-effectiveness for smaller operations, VFFS machines excel in high-speed, large-volume production environments.

Premade Pouch machines are relatively quick to set up and switch between different bag sizes, making them ideal for small to medium production runs with frequent product changes. These machines can handle various bag styles, including stand-up pouches, flat pouches, and more, providing flexibility in packaging options to cater to consumer preferences.

However, Premade Pouch machines may have limitations in terms of speed, especially for high-volume production. They can also be more labor-intensive, as operators need to load bags onto the machine and perform quality checks, potentially increasing labor costs.

VFFS machines are known for their high-speed capabilities, making them ideal for large-scale roasteries with significant production volumes that demand rapid packaging. They&#;re also masters of efficiency when it comes to continuous and large production runs, minimizing downtime between batches and maximizing output.

On the other hand, VFFS machines require a more complex initial setup, including film roll loading, forming tubes, and aligning sealing jaws, which might demand skilled operators. You also have to consider changeover challenges: Switching between different bag sizes and styles can be time-consuming and complex, potentially causing production interruptions during frequent product changes.

Variety in Product Line

The variety in your coffee product line plays a significant role in determining whether to opt for a Premade Pouch machine or a VFFS machine for packaging. Here's how this might impact your decision:

Premade Pouch Machines

1. Flexibility in Bag Styles:

   As we&#;ve already noted, Premade Pouch machines are versatile and can accommodate different bag types and sizes.

2. Quick Changeovers:

   These machines allow for relatively quick and easy changeovers between different bag sizes and styles. This is beneficial if your product line frequently introduces new variations or limited-time offerings.

3. Small to Medium Batches:

   If your product line features a range of small to medium-sized batches, Premade Pouch machines can efficiently handle the diversity in packaging requirements without excessive downtime.

VFFS Machines

1. High-Speed Performance:

   VFFS machines are designed for high-speed packaging, making them suitable for coffee product lines with large-volume items that require quick and efficient packaging.

2. Consistent Quality:

   Automated sealing and cutting in VFFS machines ensure uniform packaging quality, which is crucial if your product line needs a standardized presentation across various packaging sizes.

3. Efficiency in Large Runs:

   If your coffee product line consists primarily of popular, high-demand items, a VFFS machine can handle continuous large production runs with minimal interruptions. 

Sanitary Considerations

Both Premade Pouch machines and VFFS machines offer sanitary benefits, but there are differences to consider.

Premade Pouch machines often feature stainless steel construction, which is easy to clean and sanitize, reducing the risk of contamination and rust. The flat, horizontal orientation of Premade Pouch infeed can aid in preventing dust or debris accumulation, ensuring a clean filling process. Additionally, Premade Pouch machines may have fewer exposed moving parts, minimizing potential contact points for contaminants.

VFFS machines also frequently come with stainless steel construction, and their vertical design can contribute to maintaining a cleaner environment by allowing gravity to assist with preventing debris buildup. However, the vertical movement and complex mechanisms involved in the VFFS process may require more meticulous cleaning to prevent residue accumulation.

Aesthetic Appeal

 

Both Premade Pouch machines and VFFS machines contribute to the aesthetic appeal of your packaging, but they do so in different ways.

Premade Pouches can have a sleek, modern, or even artisanal look that resonates well with contemporary consumers. They also allow for ample space to display vibrant labels and branding, creating eye-catching packaging that stands out on the shelves and aligns with your branding.

VFFS machines, on the other hand, typically produce vertically oriented bags. While they may not offer as much surface area for label display as Premade Pouches, their compact design can create a minimalist and sleek appearance. While this can be appealing to certain demographics, others might associate it with a lack of visual excitement or vibrancy that they expect from more elaborate packaging formats. 

An expert weighs in:

"Choosing an automated packaging machine isn't just about convenience; it's about crafting an aesthetic experience. We&#;re finding that there is increasing demand for the premium quality of premade pouches, as it resonates with customers who appreciate authentic and artisanal designs evocative of their coffee-drinking experience,&#; said Jacob Resnick of Viking Masek. &#;That said, if you demand high-production throughput and only have one or two product lines, VFFS machines can produce sleek, minimalist bag designs that will impress your customers &#; and for less per bag (or impression) than premade pouches." 

Sustainable Packaging

Both Premade Pouch machines and VFFS machines offer unique advantages when it comes to sustainable, eco-responsible packaging. 

Premade Pouch Machines:

• Use pre-formed pouches, often designed to minimize material waste.

• Use pouches often made from recyclable materials, such as paper, kraft paper, or biodegradable plastics, reducing their impact on the environment.

• The process of using premade pouches in these machines can be energy-efficient, as it requires less heat and energy compared to forming and sealing pouches on-site.

• Printing directly on premade pouches can reduce the need for additional labels or coatings, minimizing the use of inks and chemicals.

VFFS Machines:

• Can create pouches with custom sizes, reducing excess material usage and ensuring a snug fit for the product. This customization minimizes waste.

• Can use recyclable plastics or compostable films, aligning with eco-friendly practices. (Film manufacturers are working hard to constantly improve eco-friendly film options that don&#;t impede packaging quality.)

• Enable on-demand packaging, reducing the need to transport premade pouches, which can decrease carbon emissions associated with transportation.

• Often include printing capabilities, allowing roasteries to print labels and graphics directly on the packaging. This minimizes the need for additional labels and their associated waste.

SUSTAINABILITY SIDE-NOTE: Regardless of the machine type you select, roasteries can contribute to sustainability by selecting recyclable, biodegradable, or compostable materials for their packaging. Additionally, by optimizing the sizing of pouches and minimizing excess material, coffee roasteries can reduce their environmental footprint and promote responsible packaging practices.

So, How Do You Choose A Premade Pouch or VFFS Packaging Machine?

We've given you a lot to consider and only focused on five key factors. This &#;at a glance&#; scorecard should help you quickly size up the qualities of each option &#; offering a quicker reveal of the choice that might be the best fit for you.

Just check off the considerations that mean the most for your coffee roastery and then tally them up at the end to get a sense of which option might be more viable for your roastery operations.

Coffee Equipment Pros Can Help

The decision to switch to automated packaging is a significant step for any coffee roastery. Both VFFS and Premade Pouch machines offer unique advantages, with VFFS machines excelling in practicality, speed, and cost-effectiveness (over time) and Premade Pouch machines showcasing more aesthetic packaging options and suitable for smaller production runs.

Coffee Equipment Pros can help you carefully assess your roastery's needs, budget, and long-term goals so that you can choose the packaging solution that aligns with your brand's vision and aspirations &#; ensuring that your coffee products stand out on shelves and delight consumers worldwide.

And it might just be that this isn&#;t an either-or decision. Some roasteries find a need for a Premade Pouch machine for their smaller, more specialized product lines and a VFFS machine to handle higher output for one or two higher-demand product lines.

Our partnership with Viking Masek means we can connect you with multiple packaging options like their 4SC-235 Rotary Premade Pouch Machine, 8S-235 Rotary Premade Pouch Machine, M250 Vertical Form Fill Seal (VFFS) Machine, and ST800 Multilane Stickpack Machine.

Plus, Viking Masek has just introduced the VFFS Velocity, billed as the fastest VFFS machine in the world, with its 300 bag-per-minute capability.

And at the time of this writing, we also have a Used Elite 8S-235 Single Lane Premade Pouch Machine available to ship to you immediately. 

Want more information on VFFS Packing Machine? Feel free to contact us.

For more information and details, call us @ 855.585. or call/text Rick direct @ 949.289..

Remember, we&#;re here to find the right commercial coffee equipment for you &#; quickly and affordably. 
Because Roasters Need To Roast&#;.

Related Products:

POUCH FILL & SEAL PACKAGING MACHINE - VIKING MASEK 8S-235 - - USED
VIKING MASEK 4SC-235 ROTARY PREMADE POUCH PACKAGING MACHINE (25 CPM)
VIKING MASEK 8S-235 ROTARY PREMADE POUCH PACKAGING MACHINE (60 CPM)
VIKING MASEK M250 VFFS VERTICAL FORM FILL SEAL (100 BPM)
VIKING MASEK ST800 MULTILANE STICKPACK MACHINE (80 CPM)
VIKING MASEK VFFS VELOCITY CONTINUOUS BAG MAKING MACHINE (300BPM)

Features to Consider when Buying a Vertical Form Fill and Seal Bagging Machine (VFFS)

When buying a VFFS bagging machine there are many important features to consider. Right Stuff Equipment as a VFFS manufacturer has outlined those important considerations below.

Controls

The PLC in the VFFS bagger controls the functionality and the operations within the machine. Allan Bradley is the most widely supported PLC in the industry. It is also the most robust and popular in most manufacturing applications in the USA. Less expensive PLC and HMI sets may have less capability, less memory, slower processing speeds and smaller screens HMI&#;s come in monochrome or color and in different sizes. The size of the screen allows the programmer to put more buttons on each page the operator interfaces with. This make navigating the pages much easier. Adding color calls attention to the operator. Examples include using Red, Yellow and Green status buttons to tell the operator the condition of an operating parameter.

Frame Construction

VFFS Frames come in various forms. The heavier the frame construction; Typically, from 2.0&#; to 3&#; box tube, the smoother the performance. Bolted frames mean more possible places for micro or bacteria to grow. They also present an opportunity to loosen over time. A welded frame is more sanitary and will provide a lifetime of stability. A stainless frame wont chip, rust or give your 3rd party auditors reason to deduct points. Other frames use less expensive carbon steel and the finish is epoxy painted or powder coated. These eventually chip and get surface rust. The epoxy finish is easier to touch up when this happens.

Remote Communication Port Via Ethernet/IP

This feature allows the manufacture technician to remotely monitor and adjust settings on the vFFS machine via Ethernet for maintenance and troubleshooting. It assists the customer with a fast, remote response for diagnosing operating problems

Film Tracking

Laminated and converted film webs often go through multiple steps in the of creating the final wound roll of film. When film gets slit, printed, laminated etc. it means it can be unwound and rewound for each step. This often creates uneven tension within the film roll. The result is that film will tend to drift left or right as it travels through the bagger. It then needs to be tracked on the bagger with a tracking system so it runs through the center line of the bagger. This allows the edges line up and make a proper fin seal. Film tracking is either done manually or automatically.

Automatic Film Tracking (AFT), means when the tension changes within the roll of film and the film wants to walk left or right, the AFT will automatically move the film carriage left or right to keep the film centered and the fin seal intact. This is accomplished by using a sensor that monitors the position of the film edge as it travels through the bagger. The entire film carriage moves which also includes the printer if it is installed. The printed image always stays in the right place. If AFT is not on the machine, then manual adjustments must be done when the film walks one direction or the other. This is done with an adjustment wheel that moves the film carriage. Losing the fin seal is a very common problem when the film tension is uneven, and the adjustment is manual. The operator often cannot react quickly enough to make the change needed to track the film properly.

AFT reduces lost film (which typically costs 5-15 cents per impression), down time, and yield loss.

 Film Unwind

Film also needs to be indexed for each bag to be filled and cut. The low-cost way to unwind the film is to the pull the film through the VFFS bagger. That can result in a couple of problems: One, the film stretches as it is pulled resulting in the position for cutting and sealing not being precise. Two, the film slips as belts try to pull the film through the process. The resistance of the film to pulling is high as it the film travels over several rollers. The pull-down belts can slip as a result. These machines typically have a film brake on the unwind section of film as a way to keep even tension on the film.

The upgraded option is to have a powered unwind of the film roll. The film is released as it&#;s needed to make bags. A dancer roller senses film tension and sends a signal to the powered unwind motor to release film. This keeps the film lightly tensioned through the machine and helps prevent stretching and belt slipping.  Higher end machines running high speed, big bags, or zippered film usually offer power unwind.

Jaw Closure Set

Jaw are normally closed through a mechanism controlled either pneumatically, stepper or servo motors. Pneumatics use air cylinders which eventually leak and need to be replaced. The variability of plant air pressure can also cause pressure drops and performance problems when pneumatics are used. They are also slower and less precise than stepper or servo motors. The result can be inconsistent end seals.

When using steppers or servos, the jaw closure can be more precisely controlled in terms of speed, dwell time and pressure. Keeping in mind that the variables that can be controlled on the VFFS machines to insure proper seals are: Pressure, Temperature and Dwell time. The stepper and servo motors improve performance in Pressure and dwell meaning more consistent and more controllable seals. Steppers can run over 100 cycles per minute. Servos are used in very high speed applications and continuous motion machines.

Deflators

Deflators are a sponge type material that gently pushes the air out of the top of the bag when the jaws close. This is done to keep the bags from having too much air in the head space.

 Top Plate

The top plate covers the top of the machine. Without the top cover, the film is exposed to the potential of material falling onto the surface as it travels through the rollers and toward the sealing area. It is also piece the filler is mounted to if a volumetric filler is used. In those cases, a heavier gauge metal is used. Scales have their own platforms so the top plate us just used to keep foreign material off the film.

Seal Cooling

Seal cooling is an option to blow air on the seals to help set the sealing of the laminate layer in the film.

This is useful when running at high speed and when a dense product is dropped into the bag. The option helps prevent fracturing of the seal when the product is dropped into the pouch as well as reducing the set time of the sealant layer after heat is applied.

Product Catcher

The product catcher allows product to drop while the jaws are in the process of sealing the previous bag. This reduces the drop time and improves cycle speed. This is important for products that are light density and don&#;t fall freely. These light products tend to &#;string out&#; as they fall into the forming tube. Examples include seasoned popcorn and snack foods.

The product stager allows heavier product to drop while the jaws are in the process of sealing the current bag. The stager also can absorb the energy of high-bulk density products minimizing the drop distance onto the horizontal seals.

Printer/Labeler

A Thermal Transfer printer allows you to put date code, lot code and other product specific information on the bag. The options mentioned above will assure the placement of the information is precise. Many brands have a specific window printed on the film where they want that information to be printed. If the film stretches, then the placement will move relative to the window. To install a printer, a printer bracket is needed. This is a universal bracket that will work on all the popular TT printers.

Some companies prefer a label on the bag. In those cases, there are labelers that can be installed on the bagger with will apply the label to the film at the forming tube station. An alternative is to place the label on the bag after it leaves the machine. Labeling is not as precise as TT printing, but common when non-Pre-printed film is used.

Load Shelf

The load shelf comes underneath the bag like a shelf to support it while its being filled. This is important when filling heavier weights in a VFFS bag. More than 1.5-2 pounds. The combination of seal cooling and the Load Shelf keeps the bottom seal from rupture while the laminate layer is finalizing the curing process. The Load Shelf then ejects the bag onto a discharge conveyor.

Bag Dimensions

The bag dimensions are measured by min and max width of the bag and min and max length of the bag the VFFS bagger can produce. Typical standard widths range from 8 to 16 inches. A wider capability offers more flexibility to run a variety of larger bags in the future. A wider bag also allows the product to fall into the larger opening faster and allows faster cycle speeds.

The bag length is determined by how long the film can be pulled and sealed on the fin seal. Typical lengths range from 10-18 inches. Many machines can do a &#;double pull&#; to allow a longer bag to be made.

 VFFS Bag Styles

• Gusset &#;Making a gusseted bag, helps utilize the space of the bag more fully and helps the bag stand up on the shelf for merchandizing purposes. It is made by tucking the film in at the bottom or top and bottom
•  Flat Bottom-This is a similar bag shape as the gusseted bag but tucks the bottom in a horizontal orientation. This further helps with the bag&#;s ability to stand up on a shelf and merchandize well.
• Doy Style &#;Doy Style bags are also referred to as Stand Up Pouches (SUP). To make a Doy style bag on a VFFS machine, special tooling is needed in the former and the jaws as well as some additional capabilities built into the bagger.

 Forming Tubes

You need different forming tubes for different width bags. The wider the bag, the larger the tube needed for the film to wrap around it. Bags widths are measured in lay flat, which means you place the bag flat on the table and measure the end seal width. If running bags with a zipper or one-way vale inserted in the film, then former needs to be made to accommodate the zipper or valve. Formers have shoulders the film travels over as the film transitions into a tube. Sticky films may require a dimpled shoulder surface to reduce friction.

 Static Elimination

Static electricity is created as some powders move inside the hoppers. Static charge can also be created as the film unwinds and passes over rollers. Some products like powders, float or cling when static electricity is present. It can cling to the inside of the bag as it is being formed, and get in the seal area as the jaws close. This can cause poor seal integrity and a bad appearance. Deionizers are available to reduce the charge in the film and powder reducing the problem. Anti-static film and be used and the anti-static material in the discharge cone is also an option when using a rotary scale to reduce the charge in the product.

 Bag Stripper

When filling light weight products such as tea and spices or small bags, the bags may tend to stick to the horizontal jaws after sealing. Seals will be compromised if there are bags stuck to the jaws. Bag strippers use compressed air to gently blow the bags off the jaws

One-way Valves

One way valves are used to control the gassing of product within the bag. Usually coffee. As the product creates gas, the one-way valve allows the gas to be released without allowing ambient air back into the bag. This helps reduce oxidation of the coffee. There are two basic styles of valves.

Hole Punch

A hang hole is often needed to merchandize the product. Holes can be mechanically or heat punched. Round or sombrero cuts are available. When hole punches are used, the top seal needs to be larger to seal enough film above and below the hole. s

Tear Notch

Tear notches are small notches removed from end seal of the bag and make opening the bag easier. The can be placed at the side or top.

 Jaw Seal and Cut Orientation

Seal patterns normally have a corrugated pattern to insure good seal integrity. They can be vertical where the corrugates pattern is in the same direction as the length of the bag. A horizontal pattern is when the corrugates direction runs perpendicular to the bag length. A 45 degree angles are sometimes used as well.

Horizontal seals typically give better seal integrity.

The corrugated pattern can have different pitch (# of corrugates per inch) and different shapes. Let the machine maker help determine the best options for you.

he bag end can be serrated or smooth end cut. The serration can also have different pitch or number of points per inch. The serration can act as a natural tear notch for opening the bag from the end.

Vacuum belts

These are used to create a vacuum between the belt and the film, creating a vacuum grip on the film. It helps reduce the wear on the belts by reducing the pressure needed to pull the film.

Nitrogen dosing

Nitrogen (N) helps extend the shelf life of products that degrade in the presence of Oxygen. Examples are nuts, granola and chips. Oxygen levels in the 2-5% range can normally be achieved by introducing nitrogen into the forming tube as the product is dropping into the formed bag. The N is delivered by a gas or compressed liquid N tank or N generator.

 Bulk Flow Metal Detection

Metal Detection is not possible with a conventional packaged metal detector if the packaging material is metalized film or foil. In those cases, bulk flow metal detectors can be mounted under the filler to inspect product as it flows into the bagger. If metal is found, the metal detector can divert the material or send a signal to the bagger to stop so the bad bag can be removed.

VFFS Specialty Machines

• Quad seal bags- This is a specialty bag used largely in the coffee industry. It has sealed edges on all four sides of the bag and square flat bottom. This is considered a specialty application      and requires special tooling and baggers set.
• Wash down version- Typical machines are rated IP 30 standard and come with control panels with the same or similar rating. Wash down machines will be required in certain environments such as dairy, USDA and IP ratings like IP 66, 67 or 69 might be required.
• Bag in Bag- This is a very specific application with one machine stacked on top of other to make small bags that then go into a master bag.
• Continuous Bagger- The clear majority of the baggers produced are intermittent in their operation. Continuous machines do not start and stop the film but run it continuously at up to 200 bpm. Many products don&#;t have the right properties to fall fast enough in discreet batches to fall into a bag at that speed.
•  Big Bag- Used a lot in pet food applications.
•  Stick Pack- Stick packs are specialty machines to make the stick that have become popular in drink mix and sweetener applications. They can come in single lane or multi lanes. Multi lanes allow for much higher production in bags per minute.
• Sachet- Either 3 sided of 4 sided machines. Often used for sugar packets or retail tea flow through bags.
• Squeegee Seals- Specialty Application for running liquids with no head space in the bag
• Rotating Jaws- Specialty application primarily employed to make a doy style bag on a VFFS. The result is the bag gets filled from the side and the doy is formed in the front.

Ancillary Equipment to a VFFS Application

VFFS Bagger machines will need additional equipment upstream and downstream. Some typical additions include:

• Equipment platform- Needed if there is a rotary Scale.
• Filler-Usually an auger, scale or cup filler mounted above the bagger to provide the proper amount of product into each bag. Different products have properties that will determine the best filler option.
• Feeder to the Filler- Bucket elevators, Pneumatic, screw and puck feeders are typically used to convey product from the floor level up to the Filler. Different products properties will determine the best way to convey material. Sometimes there will be a floor above the bagger where a hopper is filled directly above which then feeds the filler.
• Take away Conveyor- Conveyor transfers the newly made bag away from the bagger.
• Packaged X-Ray, Metal Detection and Check Weigh- Inspects for proper weight and contaminants in the bag after it has been formed and filled.
• Accumulation Table- Often, a rotary table catches the product from the takeaway conveyor so the next step of casing can be accomplished easily.
• Case Erection and Sealing- Case erection and sealing takes place manually or automatically after the product has landed on the accumulation table.
• Case Coding and Labeling- Case coding and be done with a printer or a labeler. There are many styles and each has its&#; pros and cons.

If you have any questions or comments please us  or call 303-327-. Thank you.

If you want to learn more, please visit our website Horizontal Packaging Machine.