7 Things to Look for When Choosing a VFFS for Coffee ...

Jan. 13, 2025

7 Things to Look for When Choosing a VFFS for Coffee ...

There are numerous reasons why someone may consider a vertical packaging machine for their coffee packaging needs. Your business may be expanding and you need to look at an option that saves on labor and packaging costs while handling the increasing demand. You may have aging equipment that is unreliable and causes excessive downtime. You may be transferring from pre-made, hand-filled bags to automated packaging looking for increased output of packaged product. You may be searching for a packaging system that has a small footprint.

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Before making the decision on a vertical bagger for your coffee products there are some key points that need to be researched and considered.

# 1 Gas Flushing Capabilities

The ability to package your product immediately after roasting is an important aspect of maintaining product freshness. Preventing oxygen degradation is the best way to keep your coffee tasting fresh and delicious. This is accomplished through methods, such as Aroma Perm® (Modified Atmospheric Packaging) that lowers your residual oxygen levels.

Minimum recommended oxygen levels are no more than 3%, however industry standards are typically set at 2% or less. Because the end goal is ultimately a great product that provides consumer satisfaction, a vertical packaging machine that offers low residual oxygen levels is a high priority for coffee packaging.

ROVEMA's patented Aroma Perm® Modified Atmosphere Packaging technology allows coffee producers to get below 1% residual oxygen in their ground coffee products and below 2% on whole bean products.

#2 Coffee Degassing Valve

This tiny object that goes on your flexible packaging plays a pretty big role. They prevent inflation of your package by allowing gasses to escape. When coffee beans are roasted, gasses build up inside of the beans- about 90% is carbon dioxide, and 10% nitrogen. In the following days and even weeks the coffee naturally "degasses". Coffee degassing valves keep the dreaded oxygen from getting into the bag once it is sealed while allowing the pressure to be released, something that could otherwise lead to a bag that bursts open. Coffee degassing valves can also be used to speed up the transition from roasting to packaging by shortening the amount of time that the coffee is in the WIP (Work in Process) stage.

Degassing valves perform all of these functions with a feature that allows gases to be released and at the same time, prevents oxygen from getting in. While this is typically used on premium retail coffee packages, like Stabilo® (Quad Seal) bags, interest has been increasing around the use of valves on coffee frac packs. For these foodservice coffee bags there is a surface-mounted valve, called a coupon valve, that can be applied at higher speeds which is gaining more momentum with this packaging type. A VFFS machine needs the capabilities to incorporate this application into the line while still running the desired speeds and creating a high-quality bag.

#3 VFFS Machine Run Rate

Naturally, when considering a vertical bagger for your coffee packaging needs, you want a machine that can not only meet your current production expectations but also align with your future growth projections. It's important to invest in a vertical form fill seal machine that can keep up with the demand for your product and provide long-term cost savings. This improved run and fill rate, whether it's due to transitioning from pre-made pouches or installing new machines, can lead to significant financial benefits, as illustrated in the figure below:

#4 Quality of the Coffee Bean Packaging

The package that houses your product represents your brand and the value you place on your product. It's also likely the first impression you make with a potential customer, even before they get to taste your actual product. With bag styles such as the Stabilo® (Quad Seal) bags, vertical form, fill, seal machines are able to produce sturdy, high quality bags that successfully represent the image you are trying to convey. Even features like an offset seal that provides alignment with the corners of the bag allow a crisp, clean look for the quad seal bag, with unobstructed back panels for graphics and copy.

No matter what bag shape or stand up pouch style you decide is best for your product, it needs to have gas tight, strong seals that protect your coffee product. It also should be evenly formed and consistent in size.

You want a machine that can make an aesthetically appealing package with seal integrity, clean knife cut, and will let you know if a produced bag does not meet those requirements.

#5 Quality of the Packaging Machinery

A machine that performs well, with quality parts and features is not only what is hoped for in a VFFS, but it should be expected. After all, achieving optimal OEE (Overall Equipment Efficiency) is the desired outcome for machine operations. Decreasing downtime inefficiencies saves valued labor time and costs.

A properly designed and thoughtfully engineered machine, with quality electrical and mechanical components, can help with film savings and energy consumption as well as labor costs. Overall, it will reduce direct costs and operational stress.

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#6 Support and Spare Parts Department

Receiving reliable and efficient support after the installation of your vffs coffee bagging equipment is crucial for your overall satisfaction. Having access to quick and knowledgeable responses to your questions or concerns is essential in preventing any potential downtime. Furthermore, knowing that you have ongoing support throughout the lifespan of the machine provides peace of mind. As the parts of the machine age and require replacement, having a team of experts readily available to assist you is just as vital for maintaining optimal equipment efficiency as the quality of the machine itself.

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#7 VFFS Machine Price

The price of a VFFS machine (like anything) varies depending on what you want regarding performance. If your goal is high speed packaging, flexibility in packaging styles and a machine built with a sturdy and expert design, then it may be more expensive than a machine that is geared toward one bag style with lower speeds. The complexity and excellence needed of the machine correlates with the cost. For example, a machine that makes a variety of packaging styles or formats may be more expensive than one that is producing one bag format. We have a VFFS comparison matrix available that lists different performance tiers, features and other deciding factors, if this would be helpful as well.

Vertical Form Fill Seal 101: Key Considerations

The machines convert films and other flexible substrates into bags and similar packages. The machines are used in a variety of industries, for diverse products with diverse requirements. There are similarities among users, though. The products, like liquids, powders, granulates, grains, and certain bulk items, all have flow properties.

Despite their seemingly do-all nature, vf/f/s machines are not stand-alone operations. They must be integrated into a production line, between upstream and downstream operations. The integration imposes decisions in aiming for the optimal fit. A reasonable start is an understanding of certain basics about vf/f/s machines, in the sequence of the three functions.

Forming. A roll of substrate is placed onto an unwinding roll. The substrate is pulled up, and then around and over rollers, to a forming collar and around a forming tube. The substate is formed into a package, the width of which is determined by the shape and size of the tube. The length of the package is determined by the programed distance in which side-positioned drive belts pull downward.

Filling. Positioned above the vf/f/s machine is a feeding (also called dosing or weighing) station. It drops product into the forming tube and into a package that has been given back and bottom seals (described in the next section). Dry product typically travels on an incline conveyor up to the feeding station. Liquids are pumped.

Sealing. First, vertical jaws seal the back of the package along its length. There are two types of vertical seals: overlap (or lap) and fin (or fold-over). They differ in how the inner and outer surfaces of the substrate are sealed together. An overlap seal is inner-to-outer and a fin seal is inner-to-inner. The difference in seal width, and therefore material usage, is negligible, and neither seal is inherently stronger. The choice depends on the substrate. For example, an outer surface that&#;s not readily heat-sealable is not compatible with an overlap seal.

Next, horizontal jaws seal the bottom of the package and, after the previously described filling is performed, seal the top of the package. The top seal is cut crosswise, allowing the separated package to fall onto a collection surface, such as a conveyor. After the cut, a portion of the top seal remains and becomes the bottom seal of the next package.

Decision-making considerations. All vf/f/s machines perform their namesake functions. So how does one decide among the offerings of the multitude of manufacturers? Sure, price is important. But the better concept is value, or benefits received at that price. Even then, a useful caveat is that you don&#;t want to pay for unneeded features and capabilities. That said, it could be prudent to exceed present needs in consideration of foreseeable future needs. Examples: a continuous-motion machine instead of an intermittent-motion one, or an operating speed further along the high-end of the spectrum.

All vf/f/s machines are a capital investment, so the reputation and experience of the manufacture counts greatly. Length of time in business and the number of installations in the given industry are key considerations. Other ones are the manufacturer&#;s after-sell service, parts inventory, etc. Trial runs always are revealing. As such, look for a manufacturer that can deliver samples from a supplied roll of substrate.

The machines should be of a sturdy construction, primarily consisting of stainless steel. The construction should be easy to clean or hose down, a factor that&#;s especially true for food and beverage applications.

Because of their verticality, the machines have a smaller footprint compared to horizontal machines, thereby saving floorspace. But that characteristic should not be exploited to extremes. A machine should reside within an un-cramped perimeter that allows for convenient and safe access by personnel who operate, troubleshoot, repair, and otherwise interact with the machine. The same perimeter should allow convenient and safe avoidance by personnel who have no interactions with the machine.

An easy-to-overlook consideration is how quietly (or noisily) a machine operates. Factories generate a non-symphonic mix of sounds, from production line stations, material handling equipment, etc. The higher the decibel, the more disruptive it can be to personnel-to-personnel communications.

Then there&#;s the controls cabinet, typically located at the side of the machine. Inside are the electrical components, which should be evaluated in terms of how state-of-the-art they are. On the outside are the operator&#;s controls. It has become common for those controls to be presented on a touchscreen. The extent to which the choices on the screen are easily understood, or even intuitive, bears directly on how sophisticated (and, therefore, time-consuming and expensive) operator&#;s training needs to be.

Whereas this article does not exhaust the topic, it examples the breadth of analysis required in the acquisition of vf/f/s machines. And if a company, instead, goes the route of a contract packager, the presented information can be modified accordingly.

Sterling Anthony, CPP, consults in packaging, marketing, logistics, and human-factors. A former faculty member at the Michigan State University School of Packaging, his contact info is:100 Renaissance Center, Box-176, Detroit, MI ; 313/531-; [ protected]

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