Big VFFS vs Small VFFS – The Complete Difference

I. Introduction

 This article highlighting differences between big and small VFFS （ Vertical Form-Fill-Seal Machines）machines , providing readers with a comprehensive guide for selecting the right VFFS Packing machine size for their business.

II. Overview of Big and Small VFFS Machines

First at all, what is VFFS?The VFFS is characterized by directly using roll-shaped heat-sealing packaging materials to automatically complete multiple functions such as bag making, metering, and filling, exhausting or inflating, sealing and cutting.

1.Definition and Features

• Big VFFS Machines:
  • Typically handle larger packaging sizes and high production volumes，If you have larger-sized products that need to be packaged, a large vertical machine is a good choice. This type of machine has high production efficiency and can pack 65 products per minute, but it should be noted that the packaging size range is up to 25kg.
  • This machine adopts servo motor & PLC control system,human machine with touch screen,photocell detector,digital temperature controller which makes the machine be simple and easy to operate.

• Small VFFS Machines:
  • Designed for smaller packaging sizes and lower production volumes,If you only pack small and light products and don’t have a big budget, a small vertical machine is relatively cost-effective. Packaging speeds can also reach 60 pieces per minute, but the range of packaging sizes is much smaller, with a maximum of 2.5kg.
  • With simplified design and simple operation, if you are SMEs(small or medium-sized enterprise), this machine will be more suitable for you.

2.The difference of Bag former

Large Vertical packing machine using Collar Type bag former.

The collar former is made up of a working surface with a collar-like outer surface and a circular or square inner surface. It is used to form flat bags with lap-sealed longitudinal and three-side seals. As shown in Figure below, the film is fed from the last guide roller and guided through the curved surface of the collar into the gap between the filling pipe 1 and the forming tube 2. During this process, the film naturally rolls into a cylindrical shape.

Thus, the key lies in ensuring that the transition between the curved surface of the collar and the forming tube’s surface is smooth and seamless. By wrapping a square sheet with a side length equal to the circumference of the forming tube tightly around the cylindrical surface and unfolding the upper end smoothly without wrinkles, a collar former model can be created.

Small vertical packing machine using Elephant trunk type bag former.

The elephant trunk former (shown below) combines the principles of both the collar and triangular formers and is an improved version of the U-shaped former. The elephant trunk former has guards on both sides to prevent film misalignment and poor adherence caused by an excessively long forming surface, which can affect folding and bag formation.

It is used to form flat bags with longitudinal lap seals and three-side seals from flat single films. With low motion resistance and a short filling distance, it is highly adaptable to various materials. Its design and manufacturing are relatively easy; however, it cannot accommodate changes in bag shape specifications. For the same bag shape, its structural size is larger than that of the collar former, and it is mostly used in vertical packaging machines.

3.Standard Specifications Comparison

Machine occupation space and space requirements: the small vertical machine has a maximum weight of 350kg, while the smallest large vertical machine also has a weight of 350kg, and the maximum weight can be up to 1200kg.

 Generally speaking, without installing a platform, large vertical machines take up more space and also require higher space. If you need to install a platform based on the actual material conditions, your factory will need a higher space, up to about 2-3 meters.

III. Detailed Comparison Between Big and Small VFFS Machines

1.Differences in PLC, HMI, and Automation Features:

Small vertical machines offer simplified operating processes that require only basic parameter settings such as bag length, width, and weight. With minimal training, your operators can quickly master the controls and operate the machine with ease.

The large vertical machine features a more advanced control system using PLC computer control, allowing parameter adjustments without stopping the machine.

2.Customizability and Flexibility

Both big and small vertical form-fill-seal machines, depending on the equipment they are fitted with, can handle different types of products (liquids, powders, granules).

Customization Options: Depending on the characteristics of your materials, options include a heated stirring device, perforation unit, easy-tear notch, linked packaging, foot insert, vacuum , side compression, and nitrogen gas injection.

3.Cost Implications

Machine Body Cost:

The cost of large VFFS machines generally ranges between USD 4,500 to USD 25,000 per unit, whereas small vertical machines are priced between USD 1,400 and USD 5,300. Additionally, large vertical machines weigh more, resulting in higher transportation costs. Specific costs depend on the machine model.

Maintenance and Operating Costs:

Due to varying production capacities, machines with higher output tend to wear down more quickly. In general, maintenance costs for large vertical machines are higher than those for small vertical machines. If there are issues with the auxiliary equipment of a large VFFS machine, replacement costs will also be higher.

Investment Return Analysis Based on Production Scale:

Since different models have varying production efficiencies, if high production capacity is required, the return on investment for large VFFS machines is higher.

4.Ease of Use and Maintenance

Both large and small vertical machines require regular lubrication and timely cleaning. Due to the size and parts of the machines, large vertical machines generally require a longer maintenance time.

Common issues with vertical packaging machines include untimely sealing, elevator malfunction, and difficulty in tearing the cutting blade. These issues are common in both large and small vertical machines.

Below is a simple comparison table of parameters between large and small vertical machines for reference:

IV. Applications and Use Cases

1.Large Vertical Packing Machine

In addition to large-scale production and bulk packaging, large VFFS machines are commonly utilized in the following industries:

Food Industry（Snacks Chips, popcorn, nuts, dried fruits,Flour, sugar, coffee, spices, rice, grains, Milk powder, cheese cubes.)，Chemical Industry(Fertilizers, agrochemicals, detergents, pigments, and plastic granules),Agriculture and Animal Feed，Small metal parts(nails, screws, bolts, and plumbing accessories)Household and Personal Care Products，Construction materials.

Classic Case Example:

Case1: The customer planned to package candy, requiring individual candies of a certain weight to be packed into a larger bag. The solution employed was a large vertical machine paired with a 10-head weigher to package the candy, supplemented by a chain bucket feeder. This setup achieved a packaging speed of one bag every two seconds, meeting the customer’s production capacity requirements.

Case2:The client wanted to pack snacks into individual small packages and then pack these small packages into large Bags. To achieve this, a solution combining a large VFFS machine with a Z-type elevator was adopted, enabling fully automated production of snack packaging.

2.Small Vertical Packaging Machine

Industries using small VFFS machines: trial packs, small to medium-sized products, liquids, food packaging, small hardware packaging, pharmaceutical packaging.

Examples for Small VFFS Applications:Cosmetics( laundry powder,sachets for creams, lotions, and serums)，Pharmaceuticals（single-dose packs for tablets and capsules），Spices（ sugar,salt,small pouches for herbs and seasonings）， Foods（puffed snacks, jelly, organic and health-focused food products）,Tea Bags. 

Classic Case Example:

The client needed to package small bags of mixed grains, so we designed a small vertical packaging machine equipped with an eight-head weighing system and additionally installed a chain bucket feeding system. This solution not only saved space but also effectively improved production efficiency, fully meeting the client’s capacity expectations.

V. Conclusion

Large and small vertical form-fill-seal (VFFS) machines differ in terms of production requirements, packaging size and type, budget constraints and cost-effectiveness, available space and facility layout.

When considering a VFFS machine for your company, several factors need to be taken into account: production requirements, packaging size and type, budget constraints and cost-effectiveness, available space and facility layout, future scalability needs, and production requirements. Based on these factors, you can choose the appropriate size machine.