Case study

Paper-based packaging on HFFS machines

  • Reading time 2 min

  1. Project objective

    Investigate the main factors causing processing issues when running paper-based packaging materials on HFFS machines, and identify machine-level technical solutions to improve their industrial processability.

  2. Year

    2022

  3. Lab/Division

    OPENLab site
    Lugano
    IMA division/company involved
    IMA Ilapak Lugano

Project overview

The market offers a wide variety of heat-sealable paper-based packaging materials that differ significantly in composition and behaviour during processing on HFFS machines.

While some materials can be processed with standard machine configurations, others show critical issues during unwinding, folding and forming operations, often resulting in material breakage.

OPENLab investigated the main factors influencing paper processability, including coefficient of friction between packaging layers and machine parts, mechanical properties of the material, contact surface area, forming box geometry, feeding angle into the forming section and the position of pulling rollers relative to the forming box.

Key results

  • Identification of correlations between tensile strength at break in cross direction (CD), material breakage and machine configuration, enabling early prediction of material behaviour at laboratory level.
  • Development of patented HFFS machine modules, usable either as upgrades on existing machines or combined within dedicated solutions such as the Delta 360X, to improve the processability of challenging paper-based materials.