Blown film lines don’t only serve packaging film production, they also feed into a wide range of converting processes like form-fill-seal (FFS) and polybag manufacturing. As more companies diversify their output, adapting existing blown film machinery can unlock new markets and improve return on investment.
This blog explains how to adjust your blown film setup for bag and FFS applications effectively.
Understanding Form-Fill-Seal Requirements
FFS systems form, fill, and seal bags directly from film rolls, so film must unwind evenly and maintain consistent thickness. Poor winding or web alignment can cause sealing issues or print misregistration.
Ensure your film rolls have tight, even tension and straight edges. Upgrading winding and web guiding systems helps deliver the precision needed for automated packaging. Learn more in Why Blown Film Needs Precise Web Guiding.
Adjusting for Bag Production
Bag converting machinery may require different film widths, perforations, or gussets. Adjust line settings to achieve the required dimensions without overstretching the film.
For example, switching from plain film to side-gusset bags means recalibrating rollers and nip pressure to maintain fold accuracy. Swallow’s Turning Bar & Idler Systems are ideal for smooth direction changes and stable film handling across multiple product types.
Matching Film Type to Application
Each application requires a different film blend. FFS packaging often needs sealable outer layers, while carrier bags demand higher tensile strength. Using multi-layer co-extrusion allows you to meet these varying needs efficiently.
If you’re producing eco-friendly bags, check our article on Energy-Efficient Upgrades for Legacy Blown Film Machinery for tips on optimising sustainable production.
Final Thoughts
With a few smart adjustments, existing blown film machinery can handle a wider range of products, from FFS packaging films to heavy-duty carrier bags.
Swallow offers adaptable handling systems that support smooth transitions between applications, helping you meet evolving market demands without replacing entire lines. Speak to an expert today.
Need to optimise your web processing setup?
Our experienced team at Swallow Machinery is ready to advise on the best ancillary machinery - from web guiding and tension control to air-expanding reel shafts. Get in touch today to explore how we can support your continuous manufacturing needs.
