Horizontal Flow Wrapper Product

Overview

A horizontal flow wrapper (also called a pillow-wrap machine) forms a horizontal pouch around products moving on an infeed conveyor. It combines simplicity with high throughput, making it ideal for wrapping chocolates, biscuits, ice creams, and other confectionery items in pillow or gusseted pouches.

The film is formed around the product by a fixed mandrel or folder, sealed on three sides (both ends and one side), and cut to separate pouches. Horizontal flow wrappers are faster and simpler than VFFS machines for rigid or semi-rigid products that don't require precise volumetric fills.

How it works

Products arrive on the Infeed Conveyor, driven by the Infeed Motor and spaced by the Product Guides. The Position Sensor confirms each product is in position at the forming box entrance.

The Film Reel Station supplies film at constant tension managed by the Reel Brake. Film is guided by the Film Guides and the Film Detector monitors supply.

At the Forming Box, the product passes through a Forming Plate that defines the pouch width. The Film Folders (typically pneumatic or cam-driven) fold the film sides around the product. The Folder Rollers press the overlap together to create a tight longitudinal seal via pressure alone or low-temperature bonding.

The product then moves into the Sealing Head, where the Front Seal Jaw and Back Seal Jaw clamp down. The Seal Heating Elements (nichrome wire) on both jaws heat-seal the pouch ends. Seal temperature is monitored by Temperature Sensors and regulated by the Temperature Controller via Heater Relays.

Immediately after sealing, the Cutting Unit fires. The Cutter Wire melts through the film to separate pouches, timed by the Cutter Sensor. The cut pouch drops through the Discharge Chute onto the outfeed.

All station timing is coordinated by the Drive System: the Main Motor drives the Main Gearbox, which rotates the Main Shaft carrying Cam Followers. These cams operate the folder, sealing jaw, and cutter in synchrony with the infeed conveyor.

The Control System sequences all operations via the Control Cabinet PLC. The HMI Panel allows recipe selection (pouch width, length, seal times). The Safety Module enforces the E-Stop Button and protective guards.

Film and product compatibility

Horizontal flow wrappers work best with rigid or semi-rigid products (biscuits, chocolates, ice creams, cheese, butter). The film is typically a transparent flexible film: OPP (oriented polypropylene) offers clarity and stiffness, PE (polyethylene) provides excellent seal-ability, and laminates (polyester/PE, nylon/LLDPE) add barrier properties for oxygen or moisture sensitivity.

Gusseted pouches (with side folds) are possible on modern machines with optional forming plates. Pouch speeds (40–200 pouches/min) depend on product density and seal dwell time; lighter, smaller products run faster.

Format changeover typically requires adjusting the Forming Plate and recalibrating seal and cutter positions—5–15 minutes for experienced operators.