How to optimise film for higher output and less downtime?

In automated packaging lines, film is a determining factor for both output and process stability. Many production issues are not caused by the machine itself, but by suboptimal alignment between film properties and machine settings. Optimising film is therefore a direct lever for higher efficiency and lower costs.

1. Tailor film properties to the packaging line

Important parameters such as seal initiation temperature, coefficient of friction (COF), stiffness and thickness tolerances determine how the FFS film behaves on the machine. For example, a COF that is too high or too low can lead to slip or transport problems, while inconsistent thickness causes variations in sealing and cutting performance. By tuning these properties to the specific machine configuration and speed, the foundation is laid for stable runnability.

2. Optimise sealing behaviour for higher speeds

At higher output, the available sealing time decreases. Films with a wide sealing window and fast seal response are essential to guarantee reliable closures without having to slow down the machine. In practice, this means that seal strength and consistency must be tested under realistic production speeds, not just under laboratory conditions.

3. Minimise material usage without loss of performance

Thickness reduction (downgauging) can help to reduce costs and lower material consumption, but only if the mechanical and thermal properties are maintained. A reduction of, for example, 5–15% is achievable in many applications, provided the film has been optimised for the specific load on the production line. Uncontrolled downgauging, on the other hand, often leads to more downtime and higher overall costs.

4. Testing under practical conditions

Laboratory tests provide direction, but real validation takes place on the packaging line. Factors such as product composition, environmental conditions and machine settings have a direct impact on performance. By carrying out tests on the line together with the film manufacturer, deviations can be identified and resolved at an early stage.

5. Look at the total system (TCO)

Optimisation isn't only about film price, but to Total Cost of Ownership. Less downtime, higher output and less waste often yield more than a lower material price per kilo. Combining these factors results in a more robust and cost-efficient packaging process.

Conclusion

Higher output and less downtime are rarely the result of a single adjustment. It is the combination of the right film properties, tailored to the machine and tested in practice, that makes the difference.

Curious about where your packaging line can be optimised? Contact one of our specialists and discover where immediate gains can be made.