A flow wrapper is an automated packaging system that surrounds products with a continuous flexible film. The machine forms long seals and cross seals to create a closed package.
The finished format is usually described as a pillow pack.
Unlike manual packaging methods, flow wrapping machines are built for continuous production. This makes the equipment suitable for production lines that require fast and consistent packaging.
How Do Flow Wrapping Machines Work?
Automatic flow wrapping equipment uses a continuous roll of flexible film to wrap products at a steady production rate.
1. Automatic Product Feeding
A conveyor or connected feeding system automatically moves products into the machine.
2. Packaging Film Positioning
As the item travels forward, the machine forms the flexible film around it.
3. Sealing Along the Pack
The film is sealed along its length to create a continuous tube around the product.
4. Cross Sealing and Cutting
End-sealing jaws close the package before cutting it into an individual pack.
5. Finished Product
The sealed package exits the machine and can then be stored, distributed or displayed.
Advantages of Flow Wrapping Machinery
Many manufacturers invest in flow wrapping machinery to increase production efficiency while maintaining packaging quality.
High Production Speeds
Flow wrapping machinery can process thousands of products every hour when the equipment and application allow.
Uniform Seals and Appearance
Products pass through the same controlled sealing process. This can help keep retail packs neat and recognisable.
Lower Operator Requirements
An automated system reduces hands-on work throughout the wrapping process. Staff can therefore spend less time on repetitive packaging work.
Protection During Storage and Transport
The sealed film can shield products against dirt, moisture, contamination and handling damage during warehousing, handling and delivery.
Flexible Packaging Options
Modern machines can package many product sizes and shapes using different flexible films.
Common Flow Wrapping Applications
The process can package products from several different sectors.
Products frequently packaged in this way include:
- Biscuits
- Cakes, bread products and other bakery goods
- Chocolate and confectionery
- Fruit and vegetables
- Frozen foods
- Medical products and devices
- Pharmaceutical products
- Cosmetics and personal care items
- Household goods
- Small industrial and hardware parts
Its suitability for food and non-food applications makes flow wrapping a common packaging method in manufacturing.
What Films Can a Flow Wrapping Machine Use?
The correct flexible film will depend on the item being packed and the conditions it must withstand.
Common materials include:
- Biaxially oriented polypropylene film
- Polyolefin packaging film
- Polyethylene film
- PET film
The most suitable film depends on the product, required shelf life, desired presentation and production environment.
Should Your Business Move to Automatic Flow Wrapping?
Companies often adopt flow wrapping machinery when hand packaging can no longer keep pace with demand.
You may benefit from upgrading when:
- Your required packaging output is rising
- Manual packaging slows the production line
- Pack appearance or seal quality is inconsistent
- You need more repeatable packaging results click here
- Labour costs are increasing
A suitable flow wrapper can raise output and produce more uniform packaging.
What Features Should You Look for in Flow Wrapping Machinery?
Machine selection requires an assessment of pack format, output and future demand.
Useful machine features include:
- Maximum production speed
- Product size capacity
- Easy product changeovers
- Printed-film registration using photocells
- Date and batch-code printing
- Automatic feeding integration
- User-friendly controls
- Reliable sealing performance
Machine suitability will be determined by the items being packed, required output and expected business growth.
How Do Flow Wrappers Differ from Shrink Wrap Machines?
Both systems package products in flexible material, although their operating methods differ.
Flow wrapping machinery forms film around the product before applying length and end seals.
A shrink wrap machine surrounds the product with shrink film before applying heat to tighten the material.
The choice will depend on the desired pack format, the product and how it will be stored or transported.
Can Flow Wrapping Machinery Be Added to an Existing Production Line?
In many cases, yes. Current flow wrappers may be installed as part of an established production system.
Integration options commonly include automatic product feeders, conveyors and label applicators. This allows manufacturers to add automated packaging without making major changes to the full production line.
Flow Wrapping Machinery from Kempner
Kempner UK has more than 50 years of experience supplying packaging machinery and materials throughout the UK.
Its range includes horizontal and vertical flow wrapping systems for food and non-food products.
Machines can be supplied with printed-film registration, optional coding systems and tailored configurations.
Kempner also provides installation, commissioning, servicing and ongoing technical support. These services can help businesses keep equipment operating consistently.
Frequently Asked Questions
What Does a Flow Wrapper Package?
A flow wrapping machine creates sealed film packs around individual items. These packs can help shield items while they are stored, delivered or presented for sale.
Are Flow Wrappers Used for Food Packaging?
Yes, they are. Flow wrapping is widely used for bakery goods, confectionery, snacks and fresh produce. It provides a hygienic sealed pack.
Are Flow Wrappers Suitable for Non-Food Items?
Yes, they can. Manufacturers use flow wrapping machinery for pharmaceutical products, medical devices, hardware, cosmetics and consumer goods.
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.