Buyer’s Guide: Rollstock Vacuum Packaging Equipment
“Knowing the rollstock equipment available will help you decide what best meets your packaging requirements”
Efficiency is critical when vacuum packaging products in bulk for optimal shelf life. Chamber vacuum sealers are a great, efficient option for many smaller business models. However, a commercial vacuum sealer still requires a level of time and labor which larger businesses cannot afford.
A thermoforming machine, commonly referred to by the industry term “rollstock,” are the next step up for these businesses. Thermoformed packaging requires less labor, time, and long-term costs while improving package appearance.
The “rollstock” definition is simply a commercial thermoforming packaging machine. It utilizes rollstock film to securely and consistently package items with minimal labor and time.
For most commercial vacuum sealer machines, a cycle is 30 seconds or more. Once a cycle is complete, the product also needs labeling. Reload times are longer, and for commercial food vacuum sealers, food safety could be at risk with this extra time.
Additionally, custom printed rollstock film removes the time it takes to create and stick on labels.
Factors to Consider When Choosing a Rollstock Machine
Variations exist between the rollstock machines including our JVR-certified rebuilt Rollstock machines and our manufacturing partner, Promarks. Knowing these will keep you informed on what features vary between machines to determine what best meets your high volume production needs.
1. Die size – The die size will determine what divider sets or package configurations the machine can accommodate. The first step in determining die size is measuring the dimensions of the product. Then, explore available die sizes to find the optimal fit. Finding the best die size for operations is key in the manufacturing process.
From there, business owners can decide on a variety of materials. Forming vs. non-forming film, and/or creating custom prints are the next step.
2. Machine dimensions – Since these are large units, the storage space you have available will play a role in the size of the machine you can accommodate. Highly compact rollstock machines, such as the PRS Mini series, are much more small space friendly. These machines start at as short as 7′, whereas high production form fill and seal units can exceed 20′.
3. Cycle times – This will range depending on the machine design, options, and required vacuum draw. Typically, rollstock machines can run as slow as necessary or up to 12 cycles per minute. With rollstock, high speed packaging does not sacrifice high quality.
4. Does your application require gas flush? – Adding gas functionality is not extremely simple, so deciding on it before purchase is best. Adding it to the rollstock machine before purchasing is the cheapest and most effective route. Typically, adding gas to a rollstock package requires a pin-gas die set.
Basic Overview of Rollstock Equipment
Knowing the rollstock equipment available will help you decide what best meets your packaging requirements. Especially with food packages, you’ll want to ensure adequate support and spare part availability for your rollstock.
Food can spoil quickly, so it’s important to limit down time if an unexpected failure occurs. Additionally, readily available replacement parts are far more cost efficient that an entire machine replacement.
As you read through, refer to the image below to help identify key components of the rollstock packaging machine.
1. Forming Station
Forming Films
Bottom Web (forming web): The manufacturer will provide a forming web spec document when determing die size. The forming web will always be wider than the machine’s web width, as some excess material must be available for transport chains to hold.
Thickness: During the thermoforming processes, the film thins out. Because of this, we recommend that customers choose a film thickness based on the considerations below.
JVR Industries stocks a range of 3-9 mil forming films as we focus more on flexible packaging. However, thicknesses can reach up to 16 mil for semi-rigid packaging. Discuss barrier properties needed for your packaging with the manufacturer.
- With an increased formed pocket depth, an increased forming film thickness should accompany it. This ensures package integrity.
- Similar to a commercial sealer vacuum machine, packaging sharper objects with a rollstock requires thicker forming film. Research the puncture resistence required for the item. Whether bones, sharps, or harshly textured objects, there is an ideal film thickness for you.
- If packaging appearance is a priority, a thicker film may appear higher quality.
Divider Sets
What is a Divider set: Include both the forming insert, located in the forming die, and the seal grid, located in the sealing die. The number of tracks and rows determine the configuration. Learn more about his terminology here.
The Roll of a Divider Set in Choosing a Rollstock Machine:
Our sales department can discuss with you how to determine the divider set configurations you will most commonly use. Knowing the configuration sizes needed will, in turn, determine what rollstock die size you require.
Changing Out Divider Sets: Expect to spend 4-8 minutes to change over to a different divider set. Depending on the configuration, you may need to change over the rotary knives, crosscut knives, and product support rails.
Forming Die
The forming die lift and forming head work together to mold the forming film into pockets at the forming station. As gripper chains advance film into the forming station, air compresses the film upwards, where it meets a heating plate on the forming head. This causes the sheets of plastic to become moldable.
The air compression system reverses quickly and pressure then forces the film into the forming mold to create pockets. The forming die will then vent and open, allowing the gripper chains to advance the pockets to the loading station.
2. Loading Station
After the film has advanced from the forming station, your products can then be placed into the formed pockets at the loading station. Programming in a delay between cycles can be useful for a product that needs more time between film advances.
3. Sealing Station
Top Web (non-forming web): Machine manufacturers will provide specs for film width, core size, and maximum roll diameter. Then, film is sourcable through a reliable supplier using this information.
Thickness: Since this film type does not go through a forming process, 2.5/3 mil film will suffice for most applications. However, heavier 4 or 5 mil films may be appropriate to provide higher puncture resistance for bone-in meats.
Customization: We also provide customization to amplify your packaging appearance. We offer a wide range of options, including easy-to-peel film, prints, stamps, labelers, and/or colors. Feel free to call our offices at (71)206-2500 to discuss these options.
Sealing Die
The Sealing Die Includes the seal head and seal bucket assembly. Non-forming film applies as the top layer over the pockets. Simultaneously, the vacuum seal process occurs. Valves open while the vacuum pump removes up to 99.8% of air from the packaging.
If gas flush applies, inert gas injects into the package, offering a fuller appearance. The seal plate lowers contacting the seal grid and seals the packaging creating an airtight seal.
Seal Plates
Various options are available for different packaging applications. This includes total seal plates, perimeter seal plates, and peel corner seal plates. Read more about our Rollstock Seal Bar Types to learn your options.
5. Cutting Station
Rows
Two options are available to cut the length of the rows.
Most commonly, guillotine style knives cut across the width of each row. The other option is a flying knife, which essentially “flys” across each row with a fine razor blade.
The flying knife system is simple and economical. However, they are not as efficient for thicker films or heavy products. The flying knife can cause the film to sag if used with these products.
Tracks
Rotary knives separate packages in the “track” direction and remove the outer edge that is held by the transport chains. As a result, this system produces a clean and trim package that enhances the look of your package products.
6. Trim Scrap Removal
The trimmed outer edge of film is collected by the trim scrap removal system. Suction or motorized winders are two common methods. Both systems have advantages and disadvantages that we would be happy to discuss!
Have Questions or Would like Personal Consulting?
Our team is glad to spend as much time as you need communicating about rollstock vacuum packaging machine equipment. We want to ensure that any equipment received from us is exactly what you need to succeed. Please feel welcome to email or call us any time, our business hours are from 8:30 am to 5:00 pm, Monday-Friday.
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