Printed Rollstock Film for High-Speed FFS Lines

A snack manufacturer runs high-speed form-fill-seal lines, where any variation in the printed film shows up immediately as downtime, film waste and pack rejects. They needed rollstock that behaves consistently from the first metre of the reel to the last.

Requirements

• Stable repeat length and print registration across the full reel
• Consistent web width, thickness and winding tension
• Barrier and seal performance that tolerates product in the seal area
• Longer rolls and the correct core size to cut changeover frequency

Our Solution

We supplied gravure-printed rollstock with the film structure and barrier layer specified to the snack’s shelf-life target, and held print registration tightly so pack graphics stay aligned at line speed. Roll width, core diameter, wind direction and maximum roll diameter were matched to the customer’s FFS machine so the film feeds without tension spikes. Printing, lamination and slitting are checked in house before the reels leave the plant.

Results

The line runs at its target speed with less film waste at changeover, and printed packs are visually consistent across the run. Longer reels reduce the number of stops per shift, which is where most waste on a high-speed line is generated.