Different packaging machines vary widely in speed. Vertical form-fill-seal (VFFS) and horizontal form-fill-seal (HFFS) machines typically output tens to low hundreds of bags per minute, whereas specialized multi-lane systems can reach several hundred. Pre-made (pick-and-fill) pouch machines generally run tens of bags per minute (doubling for multi-head versions), and vacuum sealers (especially single-chamber) are much slower (single digits).
Vertical Form-Fill-Seal (VFFS) Machines
Vertical baggers form bags from film roll, fill, and seal. Typical speeds range from a few dozen to several hundred bags per minute. Small intermittent VFFS models often run on the order of 20–60 bags/min.
- Bag size & format: Smaller, lightweight bags (e.g. snack packs, small flat bags) allow higher speeds, while large multi-kilogram bags or wide/gusseted bags run slower.
- Product type: Free-flowing powders or granules fill faster; viscous liquids or sticky pastes often require slower fill and dwell times, cutting speed.
- Machine motion: Intermittent machines (open/stop) top out around ~60–80 bpm, whereas continuous (servo-driven) machines routinely run 100–150+ bpm. Dual-jaw or twin-lane VFFS heads effectively double throughput under ideal conditions.
Horizontal Form-Fill-Seal (HFFS) Machines
Horizontal pouch machines fill already-formed bags or form flat pouches. Typical speeds are usually tens of bags per minute. Duplex (two-pouch) attachments can push output to ~110–120 ppm.
- Pouch style: Fastest speeds are achieved with light, stand-up or 3-side-seal bags. Heavy gusseted or multi-layer pouches (with zippers/spouts) slow the cycle.
- Motion & lanes: Rotary/continuous HFFS (multi-station turrets) are faster than linear indexers. Adding lanes or dual conveyors (duplex) roughly doubles output.
- Product considerations: Viscous fills (e.g. pastes) or delicate products may limit speed. Multi-head filling (e.g. multi-dosing or multi-spout) can maintain higher throughput.
Pre-Made Pouch Filling Machines
These machines open and fill pre-formed bags (stand-up pouches, spouted pouches, etc.). Speeds depend on complexity and automation. Single-stream machines often run ~20–70 bags/min. Dual-head or duplex units roughly double throughput.
- Bag features: Simple flat bags (no spout) fill faster. Zipper, spout, or valved pouches require extra handling (opening/closing), reducing speed.
- Automation: Fully automatic rotary loaders are fastest; manual or semi-auto systems (hand loading bags) are much slower.
Vacuum Packaging Machines
Vacuum sealers evacuate air from pouches or thermoformed trays. Rotary vacuum pouch machines (continuous “flexible canning” machines) can reach the tens of bags per minute. By contrast, chamber vacuum machines (batch-type) are extremely slow – typically only a few packs per minute.
- Continuous vs batch: Continuous/rotary vacuum systems use a multistation carousel (one set of stations for filling/opening, one for vacuum/sealing) and output tens of ppm. Single-chamber units seal one or a few at a time and output ~1–4 ppm.
- Product type: Thicker products or trays require longer vacuum time, slowing speed. Thin flexible pouches (e.g. retort pouches) cycle faster.
Factors Affecting Output Rates
- Bag size/volume: Smaller bags can be filled and sealed faster; large-volume or heavy bags limit cycle speed.
- Product flowability: Powders and free-flowing granules allow rapid dosing, while sticky, viscous, or particle-laden products slow the fill and require careful handling. Liquids may require leak-free filling equipment, which can be slower.
- Automation level: Machines with multiple fill heads, continuous motion cams, servo drives, and automatic bag loaders run at higher speeds than basic single-head or intermittent machines. Adding extra lanes or parallel stations directly multiplies output.
- Changeover and fouling: Frequent format changes or product changes (especially sticky powders) can necessitate cleaning or slow down settings, effectively reducing average output.
Summary of Bag Output Rates
| Machine Type | Speed Range (bags/min) | Notes/Examples |
|---|---|---|
| VFFS (vertical FFS) | ~5–300+ | Basic intermittent ~20–60; high-speed continuous ~200–300 (Viking Masek Velocity). Specialized dual-seal units up to ~400. |
| HFFS (horizontal FFS) | ~20–120 (up to ~400) | Single-clamp ~20–60 (e.g. Bartelt RPM ); duplex/rotary ~60–120. Small/light sachet machines (FLtècnics) up to ~400. |
| Premade Pouch Fillers | ~20–120 | Single-lane vacuum/pouch filler ~20–70 (e.g. 55); twin/rotary fillers ~100–120. High-speed spouted pouchers ~90–100+ per head. |
| Vacuum (rotary pouch) | ~20–60 (to ~100) | Typical rotary vacuum ~20–60. Compact vacuum-pouch machines up to ~60–100. Output depends on number of stations. |
| Vacuum (chamber/batch) | ~1–4 | Single-chamber sealers only a few packs per minute (Cryovac AutoVac ~3.3 cpm). Often measured in cycles/minutes rather than ppm. |
