A flow wrapper is an automated packaging system that surrounds products with a continuous flexible film. The machine forms a longitudinal seal and two end seals to create a closed package.
Because of its shape, the finished package is commonly known as a pillow pack.
Flow wrappers differ from manual packaging systems because they can operate continuously. This makes the equipment suitable for businesses that need to package large quantities efficiently.
What Is the Flow Wrapping Process?
A flow wrapping machine uses a continuous roll of flexible film to produce repeatable sealed packs.
1. Product Feeding
Products are carried into the machine by a conveyor or integrated feeding system.
2. The Film Is Formed Around the Product
The packaging film is shaped around each product as it moves through the machine.
3. Longitudinal Sealing
The machine seals the film lengthways so that it surrounds the product in a tube.
4. End Sealing and Cutting
The machine creates end seals and then separates each pack from the film web.
5. Pack Exit
The completed pillow pack leaves the machine ready for storage, transport or retail display.
Why Use a Flow Wrapping Machine?
Businesses often choose flow wrapping machines when they need faster production and repeatable packaging results.
Increased Production Rates
Depending on the machine model and product dimensions, a flow wrapper may package several thousand items each hour.
Repeatable Pack Presentation
The machine applies consistent seals and pack formatting to every item. This can help produce a consistent presentation across a production run.
Less Manual Handling
Flow wrapping machinery limits the need for employees to wrap every product by hand. Staff can therefore be assigned to other duties.
Product Protection
The sealed film can shield products against dirt, moisture, contamination and handling damage during storage and transport.
Adaptable Product Handling
The equipment can be configured for varied product formats and packaging materials.
Common Flow Wrapping Applications
A flow wrapper is suitable for a wide selection of food and manufactured goods.
Common examples include:
- Individual or grouped biscuits
- Bakery products
- Chocolate and confectionery
- Fruit and vegetables
- Selected frozen products
- Medical products and devices
- Pharmaceutical goods
- Personal care products
- Domestic and consumer products
- Hardware components
Its suitability for food and non-food applications makes flow wrapping a common packaging method in manufacturing.
Flow Wrapping Film Options
Different film materials can be used according to the packaging requirements.
Common materials include:
- BOPP film
- Polyolefin packaging film
- Polyethylene (PE)
- PET film
The correct material will be determined by the product type, storage period, presentation requirements and production setting.
When Is It Time to Use Flow Wrapping Machinery?
Many businesses move to automatic flow wrapping when manual packaging begins to restrict production.
Signs that an upgrade may be needed include:
- Your required packaging output is rising
- Hand wrapping creates a production bottleneck
- Pack appearance or seal quality is inconsistent
- Greater consistency is required
- Labour costs are increasing
A suitable flow wrapper can raise output and produce more uniform packaging.
Key Flow Wrapper Features
Several factors should be considered when selecting flow wrapping machinery.
Important features include:
- Packaging speed website
- Product size capacity
- Easy product changeovers
- Printed-film registration using photocells
- Integrated date or batch coding
- Compatibility with automatic feeding systems
- Clear operator controls
- Consistent and dependable seals
Your product range, packaging volume and projected demand should guide the final machine specification.
Flow Wrapping Versus Shrink Wrapping
Although both methods use flexible film, the packaging processes are different.
A flow wrapping machine forms a sealed pillow pack from a continuous roll of film.
A shrink wrap machine surrounds the product with shrink film before applying heat to tighten the material.
The right method depends on the required appearance, product type and handling conditions after packaging.
Can Flow Wrapping Machinery Be Added to an Existing Production Line?
In many cases, yes. Flow wrapping machinery can often be integrated with equipment already in use.
The machine can work alongside feeding units, conveyor systems and labelling equipment. This allows manufacturers to increase packaging output without rebuilding the entire production process.
Kempner Flow Wrapping Systems
Kempner has supplied packaging machines and materials across the UK for over five decades.
Kempner supplies both horizontal and vertical machines that can be configured for different product types.
Available options include photocell registration, date or batch coding and machine configurations for specific production needs.
Kempner also provides installation, commissioning, servicing and ongoing technical support. These services can help businesses keep equipment operating consistently.
Questions About Flow Wrapping Machinery
What Is a Flow Wrapping Machine Used For?
A flow wrapping machine creates sealed film packs around individual items. These packs can protect products during storage, transport and retail display.
Can Food Be Packaged with a Flow Wrapper?
Yes, they are. Flow wrapping is widely used for many bakery, confectionery, snack and fresh-food applications. It provides secure and hygienic packaging.
Can Flow Wrapping Machinery Package Non-Food Products?
Yes. Manufacturers use flow wrapping machinery for medical items, pharmaceuticals, small components, personal care goods and household products.
How Many Products Can a Flow Wrapper Package?
Operating speed depends on the machine and the product being packaged. Many high-performance machines can wrap several thousand products per hour.