Horizontal and vertical form fill seal (HFFS and VFFS) systems allow food manufacturing facilities to automate the packaging process. You can use these systems to fill bags of chips and other common snacks. These precise, high-speed machines differ in that one packs snacks horizontally while the other does so vertically, offering flexible and adaptable solutions, depending on the product.
Maintaining horizontal and vertical fill systems is vital for their operational efficiency and product integrity. This machinery must be inspected, cleaned, and lubricated on a routine basis to prevent obstructions, leaking seals, jams, product inconsistencies, and safety hazards that put your staff and facility’s integrity at risk. Below, our team at TDI Packsys, an industry-leading provider of food automation technology, explains key maintenance tasks, troubleshooting techniques, and best practices for HFFS and VFFS systems.
Preventative Maintenance Practices for Reliable Operation
Routine maintenance prevents costly repairs, downtime, safety risks, and efficiency concerns. We recommend developing your maintenance routine based on manufacturer recommendations and machine usage. From there, follow these tips:
Developing Your Maintenance Routine
Your upkeep routine should include daily, weekly, and monthly tasks that cover all required system tune-ups. Here are examples of what your schedule may look like, depending on manufacturer requirements:
- Daily tasks: Inspecting critical parts before use, basic cleaning, and verifying operational criteria (i.e., speed, temperature, etc.)
- Weekly jobs: Lubricating moving parts and deep cleaning of all components
- Monthly upkeep: Calibration measurements, in-depth inspections, replacing any worn parts, performing accuracy tests, etc.
After developing your maintenance routine, be sure to assign workers in charge of each critical duty and allot time during the work day for them to complete their tasks. This ensures nothing gets overlooked during busy work days.
Following Recommended Cleaning Methods
Regular machinery cleaning prevents product contamination and ensures proper function. You should follow the procedures set by your manufacturer, detailing safe cleaning agents and disassembly guidelines. In general, the process typically involves the following steps:
- Turn off the machine and disconnect it from all power sources.
- Using a non-abrasive pad or soft-bristled brush, remove debris from all surfaces, including the sealing jaws, film rollers, and forming tubes.
- Use a lint-free cloth with a food-safe cleaning product (like mild dish soap) to clean all surfaces that come in contact with the product.
- Clean the cutting knives, haws, and other sealing components using the same method.
- Conduct a visual inspection of the exterior. If you see any dirt or grime, wipe it off with a cloth.
- Once finished and dry, reconnect to power to ensure all components operate correctly.
Inspecting and Replacing Worn Components
Replacing worn components promptly prevents inefficiency, premature failure, system malfunctions, and other costly mistakes that your packaging facility likely doesn’t want to deal with. When maintaining horizontal and vertical fill systems, your team must know how to inspect each component for early signs of wear.
Some parts prone to early wear include the sealing jaws, cutting blades, and belts, as they face high-traffic usage. Reference your manufacturer’s guidelines to see how these parts should look and operate. If you notice material deterioration, uneven wear, rust or corrosion, misalignment, or poor performance despite troubleshooting, it may be time for replacement.
You should schedule regular inspections and timely replacements to prevent unexpected failures.
Lubricating Moving Parts
Proper lubrication of moving parts reduces friction and prevents premature wear. To ensure optimal results, apply lubrication after following the cleaning procedures outlined above. Select a food-grade lubricant, as it may come into contact with the product.
We recommend applying it to the rolling bearings, gears, and chains. Depending on the specific part and your manufacturer’s specifications, this may be necessary weekly or monthly. You may also need to purchase different types of lubrication for each component.
Basic Troubleshooting Solutions for Common Fill System Malfunctions
Maintaining horizontal and vertical fill systems prevents many common issues, but you still may face malfunctions. Here are simple troubleshooting tips for common problems with HFFS and VFFS systems:
For Film Alignment Issues
If the film keeps running off the center or isn’t tracking properly, you have an alignment issue. First, check the film is centering on the spindle. If it wasn’t threaded properly, you may need to re-center it to prevent this issue from occurring again.
We also recommend inspecting for any obstructions that may be throwing it off-center. You can prevent these issues in the future by requiring your team to conduct basic component checks every morning before beginning operation.
For Sealing Problems
Weak, incomplete, or leaking seals compromise your product quality and safety. We recommend adjusting the sealing temperature or pressure to see if that fixes your issue. You may also need to play around with the dwell time.
If setting changes do not resolve the problem, clean the sealing surfaces and inspect for debris. If any components are damaged, replace them promptly.
For Inconsistent Performance
You expect each product to be nearly identical. When you begin noticing variations in bag sizes or product quantities, check your machine settings to ensure nothing has changed.
Assuming your settings are correct, we recommend inspecting the film tension, which should be consistent. You may also need to calibrate the filling mechanisms.
For Frequent Jams and Spillage
When your machinery keeps getting jammed or stopped due to spills, your facility faces downtime and profit losses. You can prevent this with proper maintenance, as you must regularly clean the machine to remove debris that can cause clogs. You should immediately check for obstructions and lubricate moving parts to ensure smooth operation.
After cleaning and lubricating, run a test to verify the proper synchronization of machine components. If anything disrupts the flow, you need to correct the alignment or replace the component to fix your system.
Our Top Tips To Ensure Efficiency With Your HFFS and VFFS Machines
Efficient operation with your HFFS or VFFS machinery goes beyond basic care tasks. We also recommend the following best practices:
- Continual operator training: Your operators should be well-trained in machine operation, maintenance procedures, and safety protocols. By providing continuous education on the latest technologies and troubleshooting techniques, you can prevent manual error.
- Detailed documentation: Be sure to maintain detailed records of upkeep activities, repairs, and replacements. With detailed logs of machine performance, you can predict future maintenance needs.
- Use of quality materials: You should only use high-quality packaging materials that are compatible with your machines to prevent operational issues. We recommend regularly assessing material quality to avoid problems like poor sealing or machine jams.
- Strict environmental control: Your staff must maintain a clean and controlled environment around the machines to reduce contamination and wear. Aside from routine cleaning, you should implement proper ventilation and dust control measures to prevent debris build-up and unsafe humidity.
Key Takeaways for Optimizing Your System’s Performance
Maintaining horizontal and vertical fill systems ensures the longevity and efficiency of your facility’s critical packaging machinery. With preventive maintenance tasks, regular operator training, thorough documentation, and adherence to manufacturer guidelines, you can enjoy consistent product quality and operational excellence.
If you’re in the market for a new VFFS automation system, contact TDI Packsys today at (877) 834-6750 to learn more about our state-of-the-art machinery and how it could enhance your production.
