Esko Australia, with its long-term partner Alfa Machine, is bringing new FFS technology to Australia and New Zealand.
Form-Fill-Seal (FFS) Tub technology is one of the most efficient and cost-effective solutions in the modern packaging world.
In a compact footprint, a FFS machine integrates three primary processes in one machine:
- Forming: Using a flat roll, film is fed into the packaging machine, where it is formed into a tub or cup, creating the container for the product.
- Filling: The container is then filled with the product (such as liquid, paste, or fruit pieces), either by volumetric filling, weight-based filling, or combination of filling.
- Sealing: After filling, the container is sealed to ensure the contents remain protected and fresh.
Alfa machine with 40-year history of making filling machines recently exhibited the first production multipack Form-Fill-Seal machine using mono Polypropylene with PP In-Mold-Labelling.
Ready to Recycle
With a proactive approach to sustainability, ESKO Australia partner Alfa Machine have invested 3 years of development to run on recyclable materials such as mono PET (Polyethylene terephthalate) or PP (Polypropylene) films.
The decision to use these 2 very different materials is due to the different directions local regulations around the world have taken on recyclability and requirements of food manufacturers.
Traditionally FFS have used Polystyrene plastic because it was one of the earliest and most available plastics in the past, however this has been gradually phased out for food containers due to health concerns of Bisphenol A (BPA) used to make polystyrene.
PET & PP have very different properties that serve different applications. The choice of material comes down to customer requirements. PP is especially challenging to use but is critical for foods that need to be heated, hot filled or retorted. This material also expanded the use of FFS technology beyond the yogurt and dips food market.
Cost Effectiveness and Improved Quality
One of the most significant advantages of FFS technology is its cost-efficiency. Traditional tub packaging methods often require multiple processes – separate forming, filling, and sealing stages – using different machines and labor at each step. In contrast, the FFS integrates all these steps into one continuous, automated system, reducing the need for manual intervention and minimising production time.
Fewer steps also mean less handling, reducing chances of contamination during the transport and storage of the containers, which ensures better product protection and improves the overall quality of the packaged goods.
For products sensitive to contamination, Alfa FFS offers the option for Modified Atmosphere Packaging, Laminar flow – Ultra Clean sealed environment reduces the risk of exposure to external elements that could compromise the product.
Working with the customer, we will design the FFS to suit local regulations and your requirements. Contact Esko Australia to explore how the latest Form-Fill-Seal technology can be used for your product and the turnkey packing solution Esko Australia can provide.
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