Why It’s Critical to Understand Your Co-Packer’s or Form, Fill, Seal Machine’s Specifications for Custom Printed Rollstock
When it comes to custom packaging, particularly for products using printed rollstock, understanding the specifications of the co-packer’s or form, fill, seal (FFS) machine is absolutely critical. While the design of the packaging and the artwork are undeniably important, so is ensuring that the product can be efficiently and accurately packaged on the machines used during the production process.
Whether you’re manufacturing food, cosmetics, or any other consumer goods, getting the packaging right is key to maintaining product quality, efficiency, and cost-effectiveness. Here’s why understanding these machine specifications should be a top priority.
What Is Custom Printed Rollstock?
Before diving into the specifics of the machinery, let’s clarify what we mean by custom printed rollstock. Rollstock is a continuous roll of flexible material that is printed with artwork and used to create bags, pouches, or other types of packaging. Custom printed rollstock is tailored to your design needs and is used by manufacturers to create finished packaging with your branding.
However, for this to work seamlessly in the production process, the rollstock must be compatible with the form, fill, seal machinery used to package the product. These machines take the rollstock material, form it into the desired shape (like a pouch or bag), fill it with the product, and then seal it shut.
Why Are Specifications So Important?
Understanding the specifications of your co-packer’s or FFS machine ensures that the custom printed rollstock is not only visually appealing but functional and fit for the machine’s needs. Here’s why this understanding is so vital:
1. Machine Compatibility with Material
Different machines have varying tolerances and limitations when it comes to material thickness, width, and strength. Custom printed rollstock must be within these specifications to ensure smooth operation on the FFS machine. If the material is too thick or thin, it could cause issues during the production process, leading to downtime, production delays, or even damage to the machinery.
By understanding the exact machine specs, you can work with your supplier to select the appropriate material that won’t cause complications down the line.
2. Printing Registration and Alignment
The alignment of your custom printed artwork is critical for packaging consistency. FFS machines need precise registration, meaning the print on the rollstock must be aligned perfectly with the cutting, forming, and sealing process.
If the artwork isn’t aligned correctly with the machine’s cutting or sealing areas, the final product may end up with misprinted graphics, improperly placed logos, or even unusable packaging. Knowing the machine’s specifications helps you plan your artwork to match the print-to-package positioning accurately.
3. Speed and Efficiency of the Production Line
Different FFS machines operate at different speeds and have unique cycle times. Understanding your machine’s specifications allows you to choose rollstock that works optimally within these parameters. Custom printed rollstock that isn’t designed for the machine’s specific speed can result in slower production rates, ultimately affecting your timelines and increasing costs.
By syncing your rollstock with the machine’s speed and capabilities, you’ll ensure smoother production processes, quicker turnaround times, and reduced production bottlenecks.
4. Seal Strength and Durability
The sealing process is an essential part of packaging, especially when it comes to custom printed rollstock. Each FFS machine has specific sealing requirements in terms of temperature, pressure, and dwell time (the amount of time the material is under pressure during sealing).
If your custom printed rollstock isn’t designed to meet these sealing requirements, the packaging may not seal properly, leading to leaks, contamination, or compromised product integrity. Working with the right machine specifications ensures that your packaging will remain intact and secure throughout its lifecycle.
5. Cost-Effectiveness and Waste Reduction
Understanding your co-packer’s or FFS machine’s specifications can also reduce waste and improve cost efficiency. If the rollstock isn’t compatible with the machine, it may result in extra waste due to misalignment, damaged rolls, or poorly sealed packages. This not only adds to material costs but also increases labor and time spent on rework or machine troubleshooting.
By selecting custom printed rollstock tailored to your machine’s specifications, you minimize errors and reduce the risk of costly mistakes during production.
The Bottom Line: Efficiency Starts with Compatibility
For any company looking to use custom printed rollstock for their product packaging, understanding your co-packer’s or FFS machine’s specifications isn’t just helpful—it’s critical. Whether it’s ensuring proper alignment, optimizing machine speed, or guaranteeing the final product’s integrity, machine compatibility is the cornerstone of efficient and effective packaging production.
Taking the time to understand these details up front will save you time, money, and frustration down the line, ensuring that your product is packaged correctly and efficiently without unnecessary delays or defects.
Want to streamline your packaging process and get the most out of your custom printed rollstock? Contact us today for a free consultation and learn how we can help you choose the right materials for your machines.
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