VFFS Forming Set for Dubai Style Chocolate
A leading UK-based confectionery manufacturer, well-known for producing the popular Dubai style chocolate bars, approached BagForm to design a VFFS forming set for one of its production lines.
They were transitioning to a recyclable, paper-based packaging film and needed a forming set that could handle the new material smoothly while preserving the premium look and feel of their chocolate packaging.
The Challenge with Paper Based Packaging
Switching from conventional plastic laminate to paper-based films is increasingly common as brands focus on sustainability.
However, paper films present a unique set of challenges: they are slightly stiffer, have more surface texture and tend to generate more friction than plastic.
These characteristics mean that, when run over forming shoulders designed for plastics, paper films can drag, crease or show scuff marks.
For a confectionery product like Dubai chocolate, widely recognised and associated with quality. Consistent, unmarked packaging is essential.
Adjusting the forming set shoulder
The customer’s existing VFFS forming set was designed to package with plastic film, featuring a relatively steep shoulder angle. During initial trials with the paper-based film, our team observed increased resistance as the film wrapped around the shoulder, which occasionally left visible surface marks.
To resolve this, we re-profiled the forming shoulder, creating a gentler angle to reduce the bend radius and make the film path more gradual. This adjustment reduced friction between the paper and the forming set, helping the film glide more easily and protecting the printed surface from abrasion.
The change also reduced strain on the machine’s pull belts and allowed the production line to maintain efficient speeds.
Adding approach rollers for better film control
The redesigned shoulder improved the flow of the film, but it also required more controlled film feeding. To achieve this, we added a pair of approach rollers just before the forming shoulder.
These rollers help stabilise the film’s path, ensuring that it enters the former at the correct angle and remains properly aligned.
By minimising lateral movement and smoothing out the feed, the approach rollers helped maintain bag shape, print registration and seal quality, all of which are crucial for premium confectionery packaging.
Testing and fine-tuning
Once the forming set was installed on the production line at the UK site, we carried out a series of live trials. We monitored how the paper film behaved at production speeds, checked for any tracking issues, and made precise adjustments to the roller positions to optimise performance.
The results were positive: the film ran smoothly, with reduced drag and no visible marking on the packaging, while maintaining consistent output.
The result
The new forming set is now in full operation at the manufacturer’s facility, producing high-quality recyclable paper-based packaging for their Dubai style chocolate products.
By adjusting the forming shoulder geometry and adding approach rollers to improve film guidance, we helped the manufacturer transition to a more sustainable packaging solution without compromising efficiency or presentation.
This project demonstrates how targeted adjustments, such as modifying the forming shoulder angle and incorporating additional film control, can significantly enhance the capability of existing VFFS machinery to accommodate new packaging materials.
BagForm’s approach ensures that forming sets are designed not only for the machine but also for the specific film and product, enabling a seamless shift to sustainable packaging formats.#
BagForm is a UK-based manufacturer of vertical form fill seal (VFFS) forming sets for use on VFFS machines.
With decades of experience across food, confectionery and other industries, we focus on the small engineering details that make a big difference, from optimised shoulder geometry to precise film handling solutions.
Whether you’re looking to adapt an existing forming set for new sustainable materials or design a bag former from the ground up to improve packaging line performance, BagForm can deliver reliable results tailored to your product and production needs.