High-speed Roll Film for a Dutch Nut Packer's VFFS Line
Fixing inconsistent film tension and slip to restore rated line speed with zero seal failures.
A Dutch nut packer's VFFS line was running well below its rated output because of inconsistent film tension and slip. We supplied PET/VMPET/PE roll film with matched COF, printed with registration marks tuned to their eye-mark sensor, and ran a trial roll on site before committing to full production.
The Challenge
What the brand was up against
Before switching, the client faced several technical and commercial issues that the previous supplier could not solve.
- Line speed stuck at ~60% of rated output — costing the packer throughput.
- Frequent seal failures and film jams caused by inconsistent tension and slip.
- Existing film supplier's registration marks did not match the machine's eye-mark sensor contrast.
- Any change had to be validated without stopping the production schedule.
Our Solution
What we designed and delivered
Every step was handled in-house — design, engraving, printing, lamination and bag making.
- Supplied PET/VMPET/PE roll film, 90 μm, with COF matched to the machine's specification.
- Printed registration marks with the contrast required by the packer's eye-mark sensor.
- Ran a trial roll on-site under real production conditions before full production.
- Tuned rewinding tension and core diameter to the packer's unwind system.
Technical Specifications
Structure & production details
| Format | Printed roll film, 720 mm width |
|---|---|
| Structure | PET/VMPET/PE, 90 μm |
| Rewinding | Single wound, core 152 mm |
| COF | Matched to machine spec |
| Printing | 8-colour rotogravure with tuned eye-marks |
| Volume | 1.2 t per run |
The Results
What changed after the switch
100%
Rated line speed restored
0
Seal failures in trial run
1.2 t
First production run
1 trial
Roll approved before full order
We ran the trial roll on our line and the difference was obvious. Tension was consistent, seals held, and the line went straight back to rated speed. The registration marks matched our sensor without any adjustment.
Have a Similar Challenge?
Tell us what you are packing, what shelf life you need and how your line fills. We'll propose a structure and send samples.