Top 10 Types of Packaging Materials for VFFS Machine

VFFS packaging machines rely on specialized packaging materials to enable seamless vertical forming, filling, and sealing in continuous operations. These materials are pivotal in the global food industry, influencing food safety, shelf life, production efficiency, and overall costs.

How to Choose the the right packaging materials for VFFS Machines

Food Preservation: Barrier properties that shield against moisture, oxygen, and contamination to extend product freshness.

Production Efficiency: Compatibility with machines for reliable, high-speed performance.

Economic Performance: Balancing material costs, minimizing waste, and boosting profitability.

Regulatory Compliance: Adherence to stringent food safety standards and environmental guidelines.

In this guide, we'll explore the top 10 types of VFFS packaging materials to help you make informed choices for your operations.

Top 10 VFFS Packaging Materials: Properties and Applications

1. Polypropylene (PP) - Most Cost-Effective Option

Key Properties:

• Heat sealing temperature: 120-160°C
• Moderate barrier protection
• Excellent forming characteristics
• Cost index: 1.0 (baseline)

Best Applications: Dry snacks, cereals, pasta, granular products 

Why Choose PP: Lowest cost per package with reliable sealing performance up to 120 bags/minute

2. Cast Polypropylene (CPP) - Premium Sealing Performance

Key Properties:

• Lower sealing temperature: 110-140°C
• Superior clarity and printability
• Enhanced seal strength: 40-60 N/15mm
• Anti-static options available

Best Applications: Premium confectionery, frozen foods, visual appeal products 

Why Choose CPP: Reduced energy consumption with exceptional package appearance

3. Polyvinyl Chloride (PVC) - High Barrier Protection

Key Properties:

• Sealing temperature: 160-180°C
• Excellent oxygen barrier: 50-150 cc/m²/day
• Superior chemical resistance
• Precise temperature control required

Best Applications: Fresh meat, dairy products, high-fat foods 

Why Choose PVC: Maximum barrier protection for sensitive products

4. Ethylene Vinyl Acetate (EVA) - Flexible High-Performance

Key Properties:

• Low sealing temperature: 80-120°C
• Exceptional flexibility down to -40°C
• Superior puncture resistance
• Excellent hot tack properties

Best Applications: Frozen foods, liquid pouches, oil-containing snacks

 Why Choose EVA: Immediate seal strength with low-temperature flexibility

5. Polyethylene Terephthalate (PET) - Maximum Strength

Key Properties:

• High sealing temperature: 180-220°C
• Exceptional tensile strength: 200-280 MPa
• Superior chemical resistance
• Excellent clarity

Best Applications: Retort meals, acidic products, long shelf-life foods 

Why Choose PET: Unmatched mechanical strength for demanding applications

6. Polyethylene (PE) - Most Economical Choice

Key Properties:

• Sealing temperature: 120-170°C
• Excellent moisture barrier
• Lowest material cost
• Wide processing window

Best Applications: Bread, bakery products, frozen vegetables, dairy 

Why Choose PE: Best cost-to-performance ratio for moisture protection

7. PVDC/PVC Barrier Films - Maximum Shelf Life Extension

Key Properties:

• Exceptional oxygen barrier: <5 cc/m²/day
• Superior moisture protection: <0.5 g/m²/day
• 200-400% shelf life improvement
• Premium cost: 40-80% higher

Best Applications: Processed meats, cheese, coffee, pharmaceutical foods 

Why Choose PVDC: Maximum barrier protection justifying premium investment

8. OPP/CPP Laminated Films - Optimal Balance

Key Properties:

• Combined stiffness and sealing performance
• Enhanced barrier and print quality
• Excellent forming characteristics
• Superior visual appeal

Best Applications: Premium snacks, confectionery, specialty foods 

Why Choose OPP/CPP: Perfect balance of performance and aesthetics

9. Paper Laminated Films - Sustainable Solution

Key Properties:

• Food-grade paper base with barrier coatings
• Recyclable and compostable options
• Variable barrier properties
• Environmental compliance

Best Applications: Organic foods, eco-conscious brands, sustainable packaging 

Why Choose Paper Films: Environmental responsibility without performance compromise

10. Polystyrene (PS) - Specialty Applications

Key Properties:

• Low sealing temperature: 90-110°C
• Excellent clarity
• Limited flexibility
• Thermoforming compatibility

Best Applications: Yogurt lids, portion containers, rigid-flexible combinations 

Why Choose PS: Specialized applications requiring rigid components

How to Choose the Right VFFS Material: Step-by-Step Decision Framework

Step 1: Identify Product Requirements

Barrier needs: Moisture, oxygen, light sensitivity levels

Temperature requirements: Storage and processing conditions

Chemical compatibility: pH levels, fat content, alcohol presence

Shelf life targets: Days, weeks, months, or years

Step 2: Evaluate Machine Compatibility

Sealing temperature capabilities: Machine heating system specifications

Speed requirements: Bags per minute production targets

Film handling characteristics: Tracking, tension, forming properties

Quality control systems: Seal strength monitoring, leak detection

Step 3: Calculate Total Cost of Ownership

Material cost per package: Including waste factors and yield rates

Production efficiency: Speed optimization and downtime reduction

Quality costs: Defect rates and customer returns

Shelf life value: Extended storage and distribution benefits

Step 4: Verify Regulatory Compliance

FDA requirements: Food contact substance approvals

International standards: EU regulations, global market access

Migration testing: Product-specific simulant requirements

Environmental regulations: Sustainability and recycling mandates

VFFS Material Performance Comparison Matrix

Common VFFS Material Problems and Solutions

Problem: Inconsistent Seal Strength

Causes: Temperature variation, contamination, incorrect pressure Solutions: Zone-controlled heating, regular maintenance, parameter optimization Prevention: Continuous monitoring, operator training, quality protocols

Problem: Film Tracking Issues

Causes: Uneven tension, roll defects, static electricity Solutions: Servo-controlled edge guides, tension optimization, ionization systems Prevention: Material quality specifications, environmental control

Problem: Package Defects

Causes: Wrong material selection, parameter mismatch, machine wear Solutions: Material reselection, parameter adjustment, preventive maintenance Prevention: Comprehensive testing, regular calibration, operator expertise

2026 VFFS Material Trends and Future Outlook

Sustainable Materials Growth

• Bio-based films: 25-30% annual growth projected
• Recyclable structures: Mono-material designs increasing
• Compostable options: Expanding for organic food markets
• Reduced thickness: Downgauging while maintaining performance

Smart Packaging Integration

• Sensor-compatible films: Temperature, freshness indicators
• QR code integration: Enhanced print compatibility
• Active packaging: Oxygen scavengers, antimicrobial properties
• Track-and-trace: Supply chain visibility requirements

Regulatory Evolution

• Stricter migration limits: Enhanced food safety requirements
• Extended producer responsibility: End-of-life management
• Global harmonization: Standardized international requirements
• Transparency mandates: Supply chain documentation

Cost Optimization Strategies for VFFS Materials

Volume-Based Purchasing

• Quarterly commitments: 5-15% cost reductions
• Multi-material contracts: Negotiating leverage
• Inventory optimization: Balancing costs and storage
• Supplier partnerships: Long-term relationship benefits

Waste Reduction Implementation

Process optimization: Setup time reduction, parameter stability

Quality improvements: Defect rate minimization

Material recovery: Recycling production waste

Inventory management: First-in-first-out rotation

Performance Optimization

• Speed improvements: 5-15% throughput increases possible
• Energy efficiency: Lower sealing temperatures
• Labor reduction: Automated handling systems
• Quality consistency: Reduced manual interventions

Key Takeaways for VFFS Material Selection Success

Material Selection Priority: Match barrier requirements to product needs first, then optimize for machine compatibility and cost efficiency.

Performance Focus: Prioritize seal consistency and production speed over lowest material cost for long-term profitability.

Regulatory Compliance: Maintain comprehensive documentation and certification for all materials to ensure food safety compliance.

Sustainability Integration: Plan for increasing demand for environmentally responsible packaging solutions without compromising performance.

Technical Support Investment: Develop internal expertise and testing capabilities to provide value-added services differentiating from commodity suppliers.

Future Preparation: Stay informed about emerging materials, smart packaging integration, and evolving regulatory requirements to maintain competitive advantages.

This comprehensive guide provides the essential knowledge for successful VFFS packaging material selection, supporting both technical decision-making and business growth in the evolving food packaging industry..

After reviewing your options, which material is right for you? Contact our packaging specialists for a free consultation to match the perfect material to your product and machine.

FAQ

Q1: For a new product, what's the first step in choosing packaging material for VFFS Machine ?

A: Start by defining your product's core needs, such as its required moisture/oxygen barrier and target shelf life. This will significantly narrow down your material options before you even consider cost or machine compatibility.

Q2: My seals are inconsistent. Is it the film's fault or my VFFS machine's?

A: It's often a combination. First, verify your machine's sealing temperature and pressure are correct for the film's specifications. If the problem persists, the issue could be inconsistent film quality or thickness.

Q3: Are sustainable or paper-based films strong enough for high-speed VFFS machines?

A: Yes, modern sustainable laminates are engineered for strength and performance on high-speed lines. However, they may require minor adjustments to your machine's temperature and tension settings for optimal results.

Q4: What's the quickest way to lower my film costs without risking product safety?

A: Consider "downgauging" to a thinner film that offers equivalent barrier properties. Alternatively, evaluate if a simpler material like PE or PP can meet your needs instead of a more expensive laminate, but always test thoroughly before switching.

Q5: What does it mean when a film is a laminate, like PET/PE?

A: A laminate combines layers to get the benefits of each, like PET for strength and printability on the outside and PE for a reliable seal on the inside. This structure provides superior performance that a single material cannot offer alone.