Form-fill-seal (FFS) systems process up to 1,800 packages per minute, yet face increasing demands for flexibility across multiple package formats, materials, and product types. Current systems must maintain precise thermal control during sealing (typically 120-180°C) while handling both rigid and flexible materials, often with tolerances under 0.5mm for critical sealing zones.

The fundamental challenge lies in balancing high-speed continuous operation with the precise control needed for consistent package integrity across varying materials and product characteristics.

This page brings together solutions from recent research—including sensor-integrated telescopic systems, biodegradable material handling mechanisms, synchronized folding-sealing assemblies, and adaptive flow regulation techniques. These and other approaches focus on maintaining package integrity while increasing system flexibility and reducing material waste.

1. Stackable Biodegradable Packaging Pots with Interlocking Elements for Compatibility with Existing FFS Machines

EOCREP, 2024

Eco-friendly packaging solution for food products that allows using biodegradable materials in existing packaging machines. The solution involves creating stackable packs of biodegradable packaging pots that can be used in existing thermoforming/filling/sealing (FFS) machines. The packs have interlocking elements on opposite edges to connect adjacent packs into chains. This allows stacking the packs without additional equipment. The interlocking elements stabilize the stack. The packs can be made from biodegradable materials like molded cellulose. The packs can be filled and sealed using FFS machines without modification. This provides a way to transition to eco-friendly packaging without replacing the existing FFS machines.

2. Integrated Food Processing and Packaging System with Core Transfer Structure and Adjustable Flow Regulation Mechanism

DR MONIKA JAIN, 2024

A food processing and packaging system that enhances food preservation, safety, and efficiency by integrating processing and packaging steps. The system has a core structure to transfer liquids and particulates, an adjustable gate to regulate flow, and a scrubbing unit to clean. An actuation mechanism controls the gate opening. This allows precise liquid transfer, prevention of contamination, and temperature management. The integrated design improves efficiency compared to separate processing and packaging steps.

3. Packaging Material with Curved Cutout for Gas Release and Simplified Manufacturing Process

ALPHA CHEMICAL INC, 2024

Eco-friendly packaging material that releases gas without tearing or contamination, and a manufacturing process that reduces complexity, shortens time, increases productivity, and lowers costs. The packaging has sealing sections on opposite sides and a curved section with a cutout in between. This forms an internal space with an airflow path. The cutout allows gas to escape when contents expand. The manufacturing involves stacking fabrics, aligning centers, simultaneous vertical sealing/punching, cutting, and horizontal sealing.

4. Automatic Packaging Machine with Integrated Folding and Sealing Assemblies for Custom Package Formation

INTERTAPE POLYMER CORP, 2024

Automatic packaging machine that folds and seals products in customized packages without using preformed packages. The machine has a feeder, folding assembly, and sealing assembly. The feeder supplies material. The folding assembly receives products and wraps the material around them. The sealing assembly seals the wrapped material to form packages. The folding and sealing are synchronized to create customized packages without preformed forms.

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5. Packaging Machine with Internal Delimiter and Pressurized Gas System for Consistent Hydrostatic Pressure Maintenance

TETRA LAVAL HOLDINGS & FINANCE SA, 2024

A packaging machine for forming sealed packages filled with pourable products like juice or milk that allows flexible production speeds without modifying the machine. The machine has a feature to maintain hydrostatic pressure inside the tube during package formation without requiring long extensions. It uses a delimiter inside the tube, pressurized auxiliary gas, and level sensing to maintain consistent pressure for proper sealing. The delimiter prevents collapse of the product column. Pressurized auxiliary gas acts on the product column to match the inner environment pressure. Level sensing detects the column height and adjusts the auxiliary gas pressure to compensate for variations. This allows shortening the tube length needed for hydrostatic pressure compared to traditional methods.

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6. Packaging Machine with Integrated Sealing and Cutting Mechanism for Direct Formation from Sterilized Web

TETRA LAVAL HOLDINGS & FINANCE SA, 2024

A packaging machine and apparatus for forming packages of pourable products like juice or milk that allows faster and more efficient production compared to existing methods. The machine uses a unique sealing and cutting mechanism to form the packages directly from a sterilized packaging material web. The apparatus has two operative groups that cooperate to form, seal, and cut the tube into individual packages. This eliminates the need for separate tube forming and sealing steps. The packages have transverse sealing bands at each end. The machine sterilizes the web before forming, then advances it into an isolated chamber to seal and cut the packages. This enables high-speed production of aseptic packages without the need for separate sterilization and tube forming steps.

7. Integrated Liquid and Powder Pouch Packaging Device with Dual-Space Frame and Symmetrical Packaging Units

SEONG BUPACK CO LTD, 2024

A liquid and powder pouch packaging device that enables rapid and automated packaging of both liquids and powders in pouches without needing separate machines for each. The device has a main frame with upper and lower spaces. A storage hopper above the upper space holds the liquid or powder. Below the upper space are two pouch loading boxes. The lower space has a moving part that moves pouches along a closed curve path using transfer jigs. The upper space has symmetrically arranged packaging units with content supply units. This allows simultaneous packaging of liquids and powders as the moving part transports pouches between loading and packaging.

8. Rotary Table Packaging Machine with Movable Sealing Mechanism and Guide for Continuous Bag Formation

TOPAC CO LTD, 2024

A packaging machine for filling bags with material like food products. The machine has a rotary table with sealing parts that fold and seal a strip of material into bags. The sealing parts move in and out of the rotation path to form the bags. A movable seal part can engage a fixed seal part during rotation to seal the bags, or disengage to allow the material to pass. A guide mechanism moves the movable seal part between sealed and non-sealed positions. This allows the machine to continuously form and fill the bags.

9. Apparatus with Sterile Chamber for Tube Formation, Filling, and Sealing Using Pressurized Gas Sterilization

TETRA LAVAL HOLDINGS AND FINANCE SA, 2024

Packaging method and apparatus for producing sealed packages filled with injectable products like food products. The packaging apparatus has a sterilization unit, a tube forming unit, and a filling unit. Inside an isolated sterile chamber, the apparatus forms a tube from a sterilized web, fills it with the product, and seals it. An auxiliary gas compression unit sterilizes the tube's interior by pressurizing gas between the product column and a separator. This avoids needing long product columns to generate hydrostatic pressure. The pressurized gas sterilizes instead.

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10. In-Line Candy Packaging Method with Direct Post-Forming Packaging Application

INTERCONTINENTAL GREAT BRANDS LLC, 2024

Packaging comestibles like candy directly after forming instead of conditioning them first. The method involves forming the candy into its final shape using a machine, then applying packaging material while the candy is still in contact with the forming station. This eliminates the need for separate conditioning steps and allows continuous in-line packaging. The candy avoids contact with force-generating components during packaging.

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11. Laminated Barrier Paper with Polyolefin Sealant Layer and Variable Tear Strength

MEIWA PAX CO LTD, 2024

Barrier paper for packaging that allows high-speed filling and sealing of contents while maintaining low-temperature sealing properties. The paper has a laminated structure with a paper base layer, barrier layer, anchor coat, adhesive resin, and sealant layer. The base layer is 50% or more of the weight. The barrier layer traps water vapor and gases. The sealant layer is made of polyolefin resin for low-temp sealing. This allows high-speed bag making and filling at temps like 100-130°C. The paper tear strength is 300-2000 mN.

12. Continuous Dual-Surface Packaging System for Directly Formed Comestibles

INTERCONTINENTAL GREAT BRANDS LLC, 2024

Packaging comestibles like candy directly after forming and sizing to eliminate additional handling and reduce breakage. The packaging involves applying two packaging materials, one to each surface of the candy, and then sealing them together to enclose the candy. The candy is continuously conveyed from the forming station to a conveyor with a first packaging roller. This allows immediate packaging without transfer steps. The packaging material can be cut after sealing to size the packaging.

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13. Rotating Reel Shaft System with Movable Holding Member for Continuous Packaging Material Supply

TOKYO MOTOR CO LTD, 2024

Packaging material supply system for a bag-forming-fill-sealing machine that allows continuous supply of leading packaging material while setting trailing material without stopping. Multiple reel shafts loaded with packaging material rotate between a feeding position and a standby position. A rotating arm moves reels between a lock position for connecting and a standby position. A pedestal sandwiches leading and trailing material. A movable holding member temporarily fixes trailing material tip. This lets trailing material be set without reel shaft motion affecting feeding.

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14. Automated Packaging System with Blank Sheet Folding and Alignment Mechanism

WESTROCK PACKAGING SYSTEMS LLC, 2023

Automated packaging system for efficiently and securely packaging multiple items in a carton using a blank sheet. The system involves transporting the items on a conveyor with a blank sheet above them. The blank is folded around the items at the ends to form side panels. An alignment machine then bends the side panels at an angle while doubling over the top cover. This creates a box shape around the items. The folded blank is then sealed to complete the packaging.

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15. Unprinted Inkjet-Printable Multilayer Polymer Film Pouch with Integrated Production and Printing Method

SIHL GMBH, 2023

Unprinted inkjet-printable fillable pouch which is used in the food or pet food sector. The pouch includes a multilayer polymer film, a method for producing the pouch, a method for printing the pouch with inkjet-printing and a combined method of producing and printing a fillable pouch.

16. Continuous In-Line System for Direct Forming and Packaging of Comestibles on Packaging Roller

INTERCONTINENTAL GREAT BRANDS LLC, 2023

A continuous in-line method and system for manufacturing and packaging comestibles like gum that avoids the need for conditioning. The method involves forming the comestible directly on the packaging roller as it moves through the forming station. This eliminates the step of removing the comestible to condition it separately. The packaging material is applied to the comestible while it's still in contact with the forming station. This allows continuous in-line packaging without interruption. The comestible is packaged without cooling, which prevents damage during processing. The in-line packaging also allows for cutting and sealing the packaging materials around the comestible. This enables fully automated, continuous manufacturing and packaging of comestibles without requiring conditioning.

17. Linear Plastic Bottle Packaging Equipment with Integrated Injection Molding, Blow Molding, Filling, and Sealing Modules

HUNAN CHINA SUN PHARMACEUTICAL MACHINERY CO LTD, 2023

Linear plastic bottle packaging equipment that integrates injection molding, blow molding, filling, and sealing into a single continuous process to improve efficiency and eliminate separate steps like disinfection and transportation. The equipment has modules in a straight line for injection molding, blow molding, filling, and sealing. It uses a transfer mechanism to move the molded bottles between modules. This allows synchronized filling of multiple bottles at once. The blow molding module uses a preheating mechanism to warm the blanks before molding. The sealing module uses a gland, screw cap, or welding cap to seal the filled bottles.

18. Triangular Thermoform Package with Foil Sealed Mouth for Cheese Containment

SUETAS SUET UERUENLERI ANONIM SIRKETI, 2023

A packaging method for cream/processed cheeses that eliminates the need for wrapping the cheese in foil and secondary boxes. The method involves forming a triangular package body from thermoform material, filling it with cheese, then sealing the mouth with a foil sheet using a sealing mechanism. This provides a hermetically sealed package without the extra steps and costs of wrapping in foil. After filling, vibration can be applied to the package to smooth the cheese surface.

19. Rotating Workstation Device for Packaging Small Items with Overlapping Folds

THEEGARTEN PACTEC GMBH & CO KG, 2023

Simplified method and device for packaging small items like candies, tablets, etc. with overlapping folds without multiple transfers. The method involves picking up the item in a rotating workstation, packing it with forming and fixing overlapping folds, then outputting. The device has a rotating head with workstations to hold, pack, and seal the item. This eliminates transfers between heads for complete packaging. The fold fixing is optional, but helps prevent unwrapping. The device can have stationary elements or moving folding mechanisms.

20. Vertical Bag-Forming Packaging Machine with Horizontal Row Transfer System

PERFECT PACK SRL, 2023

Packaging machine for high-speed, high-quality packaging of products like pharmaceuticals, cosmetics, and food in bags. The machine forms the bags vertically from a sheet, then horizontally moves the bag rows to fill and seal stations. This allows dosing multiple products without heat exposure. The vertical forming reduces machine length versus horizontal machines. The horizontal movement keeps rows aligned for consistent filling and sealing.

21. Continuous Packaging System with Folded Film Containers and Integrated Closure Elements

22. Rotary Mechanism Mask Packaging System with Gripper-Based Mask and Pouch Handling

23. Packaging Assembly with Forming and Sealing Devices for Shaping and Sealing Tubes Containing Pourable Products

24. Robotic Arm-Based Continuous Container Filling and Closing System with Coordinated Movement Control

25. Continuous Operation Packaging System with Coordinated Robotic Arms for Simultaneous Container Filling and Closing

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