Snack Forming Sets for High-Speed VFFS Packaging
Project Overview
BagForm partnered with a global snack manufacturer to support their high-speed packaging operations with the supply of over 50 new and refurbished VFFS forming sets.
Running at speeds of 90–100 bags per minute, the manufacturer required forming sets that could integrate seamlessly with existing machinery while maintaining consistent pack quality at scale. BagForm was selected as their trusted VFFS forming set partner, delivering both technical expertise and high quality solutions.
The Challenge
High-speed snack packaging places significant demands on VFFS forming sets. At output levels approaching 100 bags per minute, even minor inconsistencies in forming geometry can lead to:
- Poor bag formation
- Seal integrity issues
- Increased downtime and waste
The manufacturer also faced ongoing challenges with their existing velcro tape backseal solution, including:
- High consumable costs
- Risk of foreign body contamination
- Inconsistent sealing performance at speed
A solution was required that would not only optimise bag-forming performance but also improve efficiency, packaging quality, and long-term cost control.
The BagForm Solution
BagForm supplied a combination of new and refurbished VFFS forming sets, all manufactured to OEM specifications to ensure precise compatibility with the customer’s existing high-speed machinery.
Key elements of the solution included:
Precisie Shoulder Geometry
BagForm worked closely with the customer to refine forming shoulder geometry, ensuring smooth film flow and consistent bag formation at high speeds.
OEM Specification Design
Each forming set was engineered to match the original machine specifications, enabling seamless integration without compromising performance.
Innovative Backseal Retrofit Solution
BagForm replaced the existing velcro tape system with its advanced backseal design, delivering:
- Reduced costs on consumables
- Lower risk of foreign body contamination
- Consistent, high-quality back seals
- Maintained performance at high production speeds
New and Refurbished Forming Sets
A cost-effective approach that provided brand new VFFS forming sets and refurbishment of existing forming sets, all meeting BagForm’s quality standards.
All forming sets were Made in Britain, supporting quality assurance, traceability and fast lead times.
The Result
The partnership with BagForm enabled the manufacturer to maintain high-speed production whilst improving packaging consistency and reducing operational risks.
This resulted in improved bag quality and seal consistency, reduced downtime and packaging issues and lowered consumable costs.
BagForm continues to support the manufacturer as their chosen VFFS forming set partner, providing high-quality, precision-engineered forming sets, fast turnaround times, ongoing technical support, and UK-based manufacturing.
Why BagForm
BagForm specialises in the design, manufacture and refurbishment of VFFS forming sets. By combining deep industry expertise with UK manufacturing, BagForm helps businesses across a wide range of industries keep packaging on track with a wide range of services and solutions.
Contact BagForm today to discuss your VFFS requirements and discover how we can support your packaging operation.