Troubleshooting VFFS Machines: Common Issues and How to Solve Them

When your packaging line stops, every minute costs money. Troubleshooting VFFS machines (Vertical Form Fill Seal machines) is an essential skill for any packaging plant operator or technician. These machines are reliable workhorses, but like any piece of equipment, they can develop issues that disrupt production.

In this guide, we’ll explore the most common VFFS problems and provide step-by-step solutions to get your machine running at full efficiency again.

1. Film Tracking Problems

Symptoms:

Film drifts to one side
Wrinkled film
Bags not sealing correctly

Causes:

Misaligned film roll
Worn or damaged rollers
Improper tension settings

Solutions:

Realign the film roll according to manufacturer guidelines.
Inspect rollers for wear and replace if necessary.
Adjust tension to ensure smooth film feeding without slippage.

Pro Tip: Regularly clean and lubricate rollers to prevent build-up that causes misalignment.

2. Poor Seal Quality

Symptoms:

Weak or incomplete seals
Seal contamination with product particles
Seal tearing when the bag is filled

Causes:

Incorrect sealing temperature
Worn or dirty sealing jaws
Product caught in the sealing area

Solutions:

Calibrate sealing temperature according to film specifications.
Clean sealing jaws daily to remove debris.
Check sealing jaw pressure and replace worn Teflon tape.

3. Inconsistent Bag Lengths

Symptoms:

Bags shorter or longer than the set length
Variation in product fill levels

Causes:

Sensor misalignment
Slipping of film drive belts
Incorrect encoder settings

Solutions:

Reposition the photo-eye or registration sensor for proper detection.
Tighten or replace film drive belts.
Verify encoder settings match the product size requirements.

4. Product Spillage or Overfilling

Symptoms:

Excess product on the sealing area
Bags overfilled or underfilled

Causes:

Faulty filler synchronization
Inconsistent product flow
Blockages in the filling system

Solutions:

Synchronize the filler and VFFS machine timing.
Check for blockages in hoppers and product chutes.
Ensure augers or weighers are functioning correctly.

5. Machine Jams

Symptoms:

Film stuck in the sealing area
Bags not dropping properly

Causes:

Improper bag cut-off timing
Film tension too high
Dull or damaged cutting blades

Solutions:

Adjust cut-off timing according to cycle speed.
Reduce film tension to allow smooth bag release.
Sharpen or replace cutting blades regularly.

6. Electrical or Sensor Faults

Symptoms:

Error messages on the control panel
Sudden machine stops

Causes:

Loose wiring connections
Sensor misalignment
Faulty control board components

Solutions:

Inspect wiring for loose or damaged connections.
Clean sensors to ensure accurate detection.
Replace faulty parts promptly to avoid prolonged downtime.

Preventative Maintenance Tips for VFFS Machines

While troubleshooting VFFS machines helps fix problems quickly, prevention is always better than a cure. Here’s how to keep your machine in peak condition:

Perform daily cleaning after production runs.
Check wear parts weekly and replace as needed.
Lubricate moving parts according to manufacturer recommendations.
Train operators on correct machine operation and basic troubleshooting steps.

If you need a deeper dive into preventative care, PMMI’s maintenance best practices for packaging machinery offer excellent guidelines for keeping your equipment running reliably.

Need Professional Help with Troubleshooting VFFS Machines?

If you’ve tried these solutions but your VFFS machine is still giving you trouble, it may be time to get expert assistance. Our team specialises in diagnosing and repairing all types of vertical form fill seal machines, ensuring minimal downtime and maximum productivity.

📞 Call us: 082 852 1458
📧 Email us: sales@sapackman.co.za
🌐 Visit: https://www.sapackman.co.za/

We’ll help you get your packaging line back up and running quickly — with long-term reliability in mind.

By mastering troubleshooting VFFS machines, you can significantly reduce downtime, extend equipment lifespan, and maintain packaging quality. A proactive maintenance schedule, combined with quick problem-solving skills, ensures your packaging line stays productive and profitable.

If your VFFS machine continues to have recurring issues despite regular maintenance, it may be time to consult a professional technician or consider an equipment upgrade.