CHAPTER THREE: DESIGN

INTRODUCTION

This chapter serves as an overview of the research method methodology employed in

the development of a Vertical Form Fill Seal (VFFS) machine . It elucidates how the
gathered information aided in the design process of the project, culminating in the
adoption of the VDI 2206 methodology .

The chosen methodology, VDI 2206, provides a structured approach to design and
develop complex Mechanical systems such as VFFS machines. It initiates by
delineating user and system requirements, which serve as the foundation for the
subsequent design phases. The ultimate aim is to create a system that fulfills the
specified requirements, or objectives, by dissecting the system into distinct domains.

In the context of the project, the V-model serves as a graphical representation of the
iterative design process, as depicted below. This model illustrates the
interconnectedness of the various design phases and emphasizes the importance of
thorough testing and validation at each stage to ensure the final product meets the
desired specifications and performance criteria.

This chapter will delve deeper into the specific research methods employed, detailing
how they were utilized to inform the design decisions and shape the development
process of the VFFS machine. Through a systematic exploration of the chosen
methodology and its application in the context of the project, this chapter aims to
provide insights into the intricacies of designing of VFFS.

V-MODEL FOR VFFS MACHINE

CONCLUSION
CUSTOMER
REQUIREMENTS

SYSTEM SYSTEM TEST

SPECIFICATION

POSSIBLE PROTOTYPE
SOLUTIONS DEVELOPMENT

SYSTEM DESIGN SYSTEM INTEGRATION

MECHANICAL DESIGN
CUSTOMER REQUIREMENTS
1. Versatility: The machine should be capable of packaging a wide range of products,
including solids of varying densities and volumes. This ensures flexibility in
production and enables the industrial hub to cater to diverse market demands.

2. Compatibility: The machine should be compatible with different types of

packaging materials and sizes, allowing for the efficient packaging of various
products such as detergents, juices, traditional porridge, and tea.

3. Reliability: The machine should demonstrate high reliability, minimizing

downtime and ensuring continuous production to meet market demands. Frequent
breakdowns should be minimized, and the system should be resilient to potential
issues.

4. Ease of Use: The machine should be user-friendly, with intuitive controls and
interfaces that require minimal training for operators. This ensures efficient operation
and reduces the need for specialized skills.

5. Affordability: The machine should be affordable to install and maintain, catering

to the budget constraints of small-scale entrepreneurs. The cost of installation and
ongoing maintenance should be justified by the benefits and efficiencies gained.

6. Ease of Maintenance: The machine should be designed for easy maintenance, with
accessible components and straightforward troubleshooting procedures. This
minimizes downtime and reduces the reliance on external maintenance personnel.

7. Adaptability: The machine should be adaptable to future changes and upgrades,

allowing for scalability and expansion as the industrial hub grows and evolves. This
ensures long-term viability and investment protection.

8. Quality Assurance: The machine should ensure the production of high-quality

products, minimizing defects and waste. Quality control mechanisms should be
integrated into the packaging process to uphold product standards.

9. Efficiency: The machine should improve overall production efficiency, reducing

waste, optimizing resource utilization, and minimizing production delays. This
includes features such as automated processes and optimized work-flows.

10. Predictive Maintenance: The machine should incorporate an instrumentation and

control system for predictive maintenance, allowing for proactive monitoring of
machine health and timely intervention to prevent breakdowns and optimize
performance.

11. Safety: The machine should prioritize operator safety, with built-in safety features
and mechanisms to prevent accidents and injuries during operation.

By addressing these customer requirements, the exemplary packaging machine aims

to revolutionize the industrial hub and serve as a model for small-scale entrepreneurs
in Zimbabwe, addressing the challenges associated with manual operations and
enhancing overall productivity and efficiency.
SYSTEM SPECIFICATIONS

Bag Styles PILLOW BAGS

3-SIDE SEALING

Bag Width 40mm TO 150mm

Bag Length 80mm TO 250mm

Product Type POWDERS AND GRANULERS

Dosing System VOLUMETRIC CUP

Running Motion CONTINOUS

Working Efficiency 40-80 BAGS PER MINUTE

Control System PLC

Max Power 2KW

Dimensions 1200mm × 1000mm× 2000mm

Max Weight 400kg

SYSTEM BLOCK DIAGRAM

 VERTICAL FORMING FILLING AND SILLING PROCESS

UNWINDING FILM
START ROLLING

LABELING

FORMING FILLING
COLLAR SYSTEM START

VETICAL
SEALING

BOTTOM
SEALING

TOP
SEALING

CUTTING
SEALED
END

FINISH

WORKING PRINCIPLE OF A VERTICAL FORM FILL AND SEAL

MACHINE
Film Unwinding:
- Initial step involves unwinding packaging film from a roll by the film
transport system.
- Film is guided through rollers to maintain proper alignment and tension.

Film Guiding and Tension Control:

- Film is guided within the machine using sensors and rollers.
- Precise tension control is crucial to prevent defects like wrinkles or
misalignment.

Film Forming:
- Film is wrapped around a forming tube and collar, shaping it into a
cylindrical tube.
- The dimensions of the final bag are determined by the size and shape of the
forming tube.

Vertical Sealing:
- Vertical sealing system seals the overlapping edges of the film using heat or
pressure.
- This creates a continuous tube for bag formation.

Filling:
- Product is dispensed into the formed tube by the filling system.
- Choice of filling system depends on product properties and desired
packaging accuracy, e.g., volumetric cup fillers or auger fillers.

Horizontal Sealing and Cutting:

- Horizontal sealing and cutting system forms top seal of the current bag and
bottom seal of the next.
- Simultaneously, a cutting mechanism separates individual bags.

Discharge:
- Completed bags are discharged from the machine, ready for further
processing or packaging.

POSSIBLE SOLUTION:
 PNEUMATIC VFFS MACHINES

Working Principle
Pneumatic Vertical Form Fill Seal (VFFS) machines leverage compressed air to
operate their sealing and cutting systems, offering a cost-effective and reliable
solution favored by small to medium-sized enterprises.

Advantages of Pneumatic VFFS Machines:

1. Cost Accessibility: Pneumatic VFFS machines boast a lower initial investment

compared to their servo-driven counterparts, rendering them more feasible for
businesses operating within constrained budgets.

2. Ease of Operation: These machines are characterized by their straightforward

operation and maintenance procedures, featuring simpler components in contrast to
servo-driven models, thereby enhancing user-friendliness.

3. Reliability and Durability: Pneumatic VFFS machines are renowned for their
robustness and consistent performance over prolonged duration, ensuring
uninterrupted productivity for businesses.

Disadvantages of Pneumatic VFFS Machines:

1. Speed and Precision Limitations: While dependable, pneumatic machines often

exhibit slower production speeds and less precise control over sealing and cutting
processes when compared to servo-driven alternatives, potentially impacting
throughput efficiency.

2. Increased Energy Consumption: The constant requirement for compressed air

imposes higher energy consumption, consequently translating to elevated operational
costs over time, posing a challenge for businesses striving for energy efficiency.

3. Flexibility Constraints: Pneumatic VFFS machines may encounter limitations in

accommodating diverse packaging materials and formats, restricting their adaptability
to varying production requirements and hindering versatility in packaging
applications.

SERVO-DRIVEN VFFS MACHINES

Working Principle
Servo-driven Vertical Form Fill Seal (VFFS) machines utilize electric motors to
precisely control their sealing and cutting mechanisms, catering to the needs of larger
enterprises and demanding production environments.

Advantages of Servo-Driven VFFS Machines:

1. Enhanced Speed and Precision: Servo-driven machines excel in providing
accelerated production speeds and meticulous control over sealing and cutting actions,
guaranteeing consistent and top-tier packaging quality.
2. Expanded Flexibility: These VFFS systems boast versatility in handling a diverse
array of packaging materials and formats, empowering businesses to meet varying
packaging requirements efficiently.
3. Energy Conservation: In contrast to pneumatic alternatives, servo-driven
machines exhibit superior energy efficiency, as they operate without the need for
compressed air, thereby reducing overall energy consumption and operational costs.
4. Advanced Automation and Control: Equipped with sophisticated software and
control systems, servo-driven VFFS machines facilitate heightened levels of
automation, real-time monitoring, and customization packaging processes, optimizing
efficiency and productivity.

Disadvantages of Servo-Driven VFFS Machines:

1. Higher Initial Investment: The initial cost of servo-driven VFFS machines tends
to be higher than that of pneumatic counterparts, potentially posing a financial hurdle
for some businesses considering adoption.
2. Complexity in Operation: The presence of intricate components in servo-driven
systems may contribute to increased operational complexity, necessitating specialized
expertise for effective operation and maintenance.
3. Potential Maintenance Expenses: While offering advanced features, the
complexity of servo-driven mechanisms may result in higher maintenance
expenditures over time, requiring periodic servicing and component replacements to
uphold optimal performance.
SYSTEM SELECTION

In conclusion, servo-driven VFFS machines offer significant advantages over

pneumatic-driven systems. They provide precise control, flexibility, and reduced
waste, while also offering energy efficiency, reliability, consistent performance, and
seamless integration with automation. These benefits collectively enhance
productivity, product quality, and overall efficiency in packaging operations, making
servo-driven VFFS machines the preferred choice for many manufacturers.

SERVO DRIVEN VFFS SYSTEM DESIGN

2.1 FILM UNWINDING
Commencing the process, the film transport system initiates the unwinding of the
packaging film from its roll. The film undergoes guidance through a sequence of
rollers to ensure precise alignment and controlled tension.

KEY COMPONENTS
 Film Roll Holder: This component securely holds the roll of packaging film in
place and allows for easy loading and replacement of film rolls.

 Film Unwinding Shaft: The film unwinding shaft is responsible for rotating the
film roll, allowing the packaging material to be pulled from the roll and fed into
the machine.

 Film Alignment Guide: This guide ensures that the packaging film remains
aligned as it is unwound from the roll. It helps prevent skewing or misalignment,
which could lead to production errors or downtime.

 Film Edge Sensor: An edge sensor may be used to detect the edges of the film as
it unwinds from the roll. This information can be used to maintain proper
alignment and tension control throughout the unwinding process.

CALCULATIONS
Bag Area=L ×W
¿ 250 mm ×150 mm
2
¿ 37 500 mm

Film Usage per Minute

¿ bag area × number of bags per minute
¿ 37500 ×60
2
¿ 2 250 000 mm

Film Lengtℎ per Minute

Film Usage
¿
T
2250000
¿
0.08
¿ 28 128 000 mm

2.2 FILM FORMATION

Subsequently, the film wraps around the forming tube and collar, taking on the shape
of a cylindrical tube. The dimensions of the final bag are determined by the size and
configuration of the forming tube.

KEY COMPONENTS

 Forming Tube: Also known as the mandrel or former, the forming tube is a
cylindrical component around which the packaging film is wrapped. It determines
the diameter of the resulting bag and provides structural support during the filling
process.

 Collar: The collar works in conjunction with the forming tube to guide and shape
the packaging film. It ensures uniformity in the bag's diameter and assists in
maintaining proper tension throughout the film forming process.

CALCULATIONS

Film Width=Packaging width × Sealing width× Handling width

¿ 150+16+16
¿ 182 mm

VERTICAL SEALING
Upon forming the tube, the vertical sealing system employs either heat or pressure to
seal the overlapping edges together, ensuring a continuous tube formation.

POSSIBLE SEALING METHODS

 HEAT SEALING
Working Principle of Heat Sealing:

Heat sealing involves the fusion of thermoplastic materials by applying heat and
pressure. It's executed by placing the materials between heated bars or dies, where
pressure is exerted to create a bond as the materials cool down. This method softens
the thermoplastic, enabling it to merge upon cooling, forming a secure seal.

Advantages of Heat Sealing:

1. Flexibility: Heat sealing is adaptable to a range of thermoplastic materials, making

it suitable for diverse packaging needs.

2. Efficiency: It's a rapid process, allowing for swift production in manufacturing,

thus enhancing productivity.

3. Strength: Heat-sealed joints offer durability, ensuring product protection during

storage and transit.

4. Economical:Heat sealing equipment is cost-effective and low-maintenance, leading

to reduced operational expenses.

5. Hygiene: It creates clean, consistent seals without adhesives, promoting hygienic

packaging.

Disadvantages of Heat Sealing:

1. Material Constraints:Limited to thermoplastics, it may not effectively seal non-

thermoplastic materials or those with high melting points.

2. Temperature Management: Proper temperature control is crucial; fluctuations can

impact seal quality.

3. Tooling Needs: Specialized sealing bars or dies are required, potentially adding to
setup costs.

4. Seal Integrity: Imperfections may occur, posing challenges for applications

requiring hermetic or high-barrier seals.

5. Environmental Impact:Energy consumption for heating raises environmental

concerns, particularly with non-renewable energy sources.

 IMPULSE SEALING
Working Principle:
Impulse sealing applies brief energy pulses to create seals. Materials are placed
between sealing jaws; when activated, electric current heats the jaws, melting and
fusing the materials. Upon deactivation, the seal cools and solidifies, ensuring
security.

Advantages:
1. Versatility: Suitable for diverse materials like thermoplastics, films, and laminates.
2. Speed: Enables high-speed production, enhancing efficiency.
3. Strength: Provides strong, reliable seals for product integrity.
4. Quick Setup: Minimal setup time allows rapid changeovers, reducing downtime.
5. Cost-Effective: Affordable and low-maintenance, minimizing operational expenses.

Disadvantages:
1. Limited Seal Width: Primarily suited for narrow seals.
2. Material Compatibility: Unsuitable for certain materials, affecting seal quality.
3. Quality Control: Requires precise parameter control for consistent seal quality.
4. Risk of Burns: Mishandling can lead to burns or damage.
5. Environmental Impact: Energy consumption raises environmental concerns.

 ULTRASONIC SEALING

Working Principle of Ultrasonic Sealing:

Ultrasonic sealing utilizes high-frequency mechanical vibrations to create heat and
pressure, bonding materials together without the need for adhesives or external heat
sources. This process involves placing the materials to be sealed between a vibrating
ultrasonic horn and an anvil or anvil wheel. When activated, the ultrasonic horn
vibrates at frequencies typically ranging from 20 to 40 kHz, creating friction and heat
at the interface of the materials. The heat softens the thermoplastic materials, allowing
them to fuse together upon cooling, forming a strong and secure seal.

Advantages of Ultrasonic Sealing:

1. Bond Strength:Ultrasonic sealing creates strong, hermetic seals without the need
for additional adhesives or heat, ensuring product integrity and protection.

2. Speed: The sealing process is fast, allowing for high-speed production and
increased efficiency in manufacturing environments.

3. No Heat Damage: Unlike traditional heat-sealing methods, ultrasonic sealing

produces minimal heat, reducing the risk of heat damage to sensitive materials or
products.

4. Cleanliness: Ultrasonic sealing produces clean, precise seals without the use of
adhesives, solvents, or consumables, ensuring hygienic packaging and reducing
contamination risks.

Disadvantages of Ultrasonic Sealing:

1. Material Limitations:Ultrasonic sealing is primarily suitable for thermoplastic
materials and may not be effective for sealing non-thermoplastic materials or
materials with high melting points.

2. Equipment Complexity:Ultrasonic sealing equipment can be more complex and

expensive compared to traditional heat-sealing equipment, requiring specialized
components and maintenance.

3. Seal Width and Depth:Achieving consistent seal width and depth can be
challenging with ultrasonic sealing, particularly for thicker or irregularly shaped
materials.

4. Tooling Requirements:Ultrasonic sealing may require custom tooling or fixtures

to accommodate specific packaging designs or materials, adding to setup costs.

5. Initial Investment: The initial investment in ultrasonic sealing equipment and

technology may be higher compared to traditional heat-sealing methods, requiring
careful consideration of cost-benefit analysis.

 COLD SEALING (PRESSURE SENSITIVE SEALING)

Working Principle of Cold Sealing (Pressure Sensitive Sealing):

Cold sealing, also known as pressure-sensitive sealing, operates without the need for
heat or adhesives. It relies on the activation of pressure-sensitive adhesive (PSA)
coatings applied to packaging materials. When pressure is applied, the adhesive forms
a bond between the materials, creating a secure seal. This sealing method is
commonly used in applications where heat-sensitive materials or products are
involved, as well as for resealable packaging solutions.

Advantages of Cold Sealing:

1. Heat-Sensitive Materials: Ideal for sealing heat-sensitive materials or products

that could be damaged by heat-sealing methods.

2. Ease of Use: Cold sealing is a simple and straightforward process, requiring

minimal setup and equipment.

3. Instant Bonding:Offers immediate bonding upon application of pressure, allowing

for fast and efficient packaging operations.

4. No Heat Required:Eliminates the need for heat sources, reducing energy

consumption and operational costs.

5. Resealable Packaging:Enables resealable packaging solutions, allowing

consumers to open and close packages multiple times while maintaining product
freshness.

Disadvantages of Cold Sealing:

1. Limited Strength:Cold seals may not provide the same level of strength and
integrity as heat-sealed or ultrasonic-sealed packages, especially for heavy or bulky
items.

2. Temperature Sensitivity:Cold sealing effectiveness can be affected by

temperature fluctuations, particularly in cold environments where the adhesive may
harden or lose its bonding properties.

3. Material Compatibility:Not all packaging materials are suitable for cold sealing,
as some may not adhere well to pressure-sensitive adhesives or may require specific
surface treatments.

4. Sealing Pressure Requirements: Achieving consistent sealing pressure across all

packages can be challenging, leading to variations in seal quality and integrity.

5. Environmental Considerations: Some pressure-sensitive adhesives used in cold

sealing may contain chemicals or solvents that could pose environmental risks if not
properly managed or disposed of.

CHOOSEN SOLUTION
HEAT SEALER
Choose a heat sealer for its reliability, efficiency, and versatility in creating strong and
secure seals on packaging films, ensuring product freshness and integrity.

KEY COMPONENTS OF A HEAT SEALER

Vertical sealing is a critical stage in the vertical form fill seal (VFFS) process, where
the edges of the packaging film are sealed together to form a continuous tube. Here
are the key components involved in vertical sealing on VFFS machines:

 Vertical Sealing Jaws: Vertical sealing jaws or rollers apply heat and pressure to
the overlapping edges of the packaging film to create a strong and secure seal.
These jaws or rollers typically run vertically along the sides of the film tube.

 Heating Elements: Heating elements are responsible for generating the heat
needed to seal the packaging film. They are often built into the vertical sealing
jaws or rollers and can be heated electrically or through other means such as hot
air or infrared radiation.

 Temperature Control System: A temperature control system regulates the

temperature of the vertical sealing jaws or rollers to ensure consistent and reliable
sealing. This system monitors and adjusts the heat output of the heating elements
based on factors such as film type, thickness, and production speed.

 Pressure Application Mechanism: Along with heat, pressure is applied to the

sealing area to ensure a tight and uniform seal. This pressure application
mechanism can vary depending on the design of the VFFS machine and may
involve pneumatic cylinders, mechanical presses, or other methods.

 Cooling System (Optional): In some cases, a cooling system may be integrated

into the vertical sealing section to quickly cool the sealed area and stabilize the
seal. This helps prevent distortion or damage to the packaging film and ensures
consistent sealing quality.

 Seal Inspection System (Optional): Some VFFS machines may include a seal
inspection system to verify the integrity of the seals. This system uses sensors or
cameras to detect any defects or irregularities in the seals, allowing for immediate
corrective action if needed.

SEALING JAWS OF A HEAT SEALER

MATERIA SEALING JAWS :CALCULATIONS

Free body Diagram

Sealing Force

Weight(mg)

AreaOf Sealing Face=Widtℎ Of Package ×(WidtℎOf Seal+ Handling Widtℎ)

¿ 160 mm ×(10 ×2+4 )mm
Tℎere is an upper ,lower sealing rail∧between tℎe two a ℎandling widtℎ
2
¿ 3840 mm
2
¿ 0.00384 m
Areaof Jaw widtℎ surface=80 mm × 24 mm
2
¿ 1920 mm
2
¿ 0.001920 m
Weigℎt of sealing Jaw=2 kg × 9.81
Average Sealing force=10 N
Bending Stresson the Jaw
 Force
σ=
Area

50
σ x=
0.00384

−2
σ x =13000 N m

19.6
σ y=
0.001920

−2
σ y =10 210 N m

Resultant =√ 10210 2+13 000 2

Resultant =22 N

−2
σ =16 500 N m

POWER TRANSMITION MECHANISM FOR THE SEALING

JAWS

1. CAM AND CAM FOLLOWER MECHANISM:

 Operation: A cam rotates to impart a reciprocating motion to a cam follower,
which in turn applies force to the sealing jaws.

Advantages:
- Precise control over motion and force.
- Smooth operation with low friction.
- Can achieve high speeds and repeatable motions.

Disadvantages:
- Complex design and manufacturing process.
- Maintenance may be required due to wear and tear.

2. RACK AND PINION:

Operation: A pinion gear meshes with a linear rack to convert rotary motion into
linear motion.

Advantages:
- Simple design.
- High force transmission capability.
- Can be used for long travel distances.

Disadvantages:
- Limited control over speed and acceleration.
- Susceptible to backlash.

3. LEAD SCREW:
- Operation: A rotating screw converts rotary motion into linear motion by driving a
nut along its length.
- Advantages:
- Precise positioning capability.
- Can provide high force output.
- Simple design.
- Disadvantages:
- Limited speed due to the thread pitch.
- Backlash can be an issue.
- Not suitable for long travel distances without additional support.

4. BELT SYSTEM:
Operation: A system of pulleys and belts transmit motion and force between
components.
 Advantages:
- Smooth operation.
- High-speed capability.
- Can transmit power over long distances.

Disadvantages:
- Susceptible to stretching and wear.
- Less precise compared to other mechanisms.
- Limited force transmission capability compared to rack and pinion or lead screw.

THE BEST MECHANISM:

Given the requirements for providing impulse forces on the sealing jaws for a VFFS
machine, the cam and cam follower mechanism stands out for several reasons:

1. Precision: The cam and cam follower mechanism offer precise control over
motion and force, crucial for consistent sealing operations in VFFS machines.

2. Smooth Operation: With low friction and the ability to achieve high speeds, this
mechanism ensures smooth and efficient operation, reducing wear on the sealing
components.

3. Customization: Cam profiles can be tailored to specific sealing requirements,

allowing for flexibility in sealing parameters such as pressure, duration, and speed.

4. Reliability: While complex in design, the cam and cam follower mechanism are
robust and reliable when properly maintained, minimizing downtime and ensuring
consistent performance over time.

Overall, considering the precision, smooth operation, customization capabilities, and

reliability, the cam and cam follower mechanism emerges as the best choice for
providing impulse forces on the sealing jaws for VFFS machines.

CAM AND CAM FOLLOWER MECHANISM

 MASS OF SHAFT CALCULATIONS
2
Volume Sℎaft =π r
−6 2
¿ 688 ×10 m
Density=7849
Mass=Density ×Volume
¿ 5.4 kg
MASS OF CAM
Volume=Surface Area× Tℎickness
−9
¿ 3254 × 10
Mass=0.256 kg

Force=Weigℎt + Impulse Force

¿¿
¿ 266 N
GIVEN THAT CAM ROTATES 180 DEGREES 60 TIMES EVERY MINUTE
π −1
ω= =π rad s
60
60
Linear speed=radius× ω
30
¿ π
1000
Linear speed=0.1m/ s
Power=Force× Velocity
¿ 27
¿ 27 × SF
42 W
30
Torque=266 ×
1000
¿8 N .m
CAM AND CAM FOLLOWER CALCULATIONS

Reaction Impulse Force Impulse Force

Cam Weight Cam Weight

Cam Weight Cam Weight

Reaction

Impulse Force Impulse Force

SHAFT VERTICAL PLANE CALCULATIONS

R 50N 50N

200mm 330mm
170mm

220mm 330mm
150mm

700mm
50N 50N R2

∑ F=R+ 50+50−(50+ 50+ R2 ¿ )=0 ¿

R=R 2
∑ M =((50 ×220)+(50 ×550)+(R ×700))−((50 × 200)+(50 ×530))
R=R 2=3 N

Section A
3N
 V M
X

M X =3 x
M 0=0
M 0.2=0.6 N
Section B
3N 50N
0.2m

V M

M X =3 x +50 (x − 0.2)
¿ 3 x+ 50 x −10
M 0.2=0.6 Nm
M 0.22=1 , 66 Nm

Section C

3N 200mm 50N

V M
X
220mm 50N

M x =3 x +50(x −0.2)− 50(x −0.22)

¿ 3 x+ 1
M 0.22=1.66 Nm
M 0.53=2.59 Nm
Section D

3N 530mm 50N 50N

 V M
X
220mm 50N

M x =3 x +50(x −0.2)− 50(x −0.22)+50(x − 0.530)

M x =53 x −25.5
M 0.53=2.59 Nm
M 0.55=3.65 Nm

Section E

3N 530mm 50N 50N

V M
X
550mm 50N 50N

M x =3 x +50(x −0.2)− 50(x −0.22)+50(x − 0.530)− 50(x − 0.55)

M 0.55=3.65 Nm
M 0.7=4.1 Nm

SHAFT HORIZONTAL PLANE CALCULATIONS

3N 3N
700mm

200mm 330mm
170mm

220mm 130mm
150mm
 3N 3N

Section A
3N

V M
X

M X =3 x
M 0=0
M 0.22=0.66 N
Section B
3N 3N
0.22m

V M

M X =3 x −3 (x − 0.22)
¿ 3 x − 3 x −0.66
M 0.22=− 0.66 Nm
M 0.35=− 0.66 Nm

Section C
3N 220mm 3N

V M
X
350mm 3N

M x =3 x −3(x −0.22)−3(x −0.35)

M 0.35=0.66 Nm
 M 0.53=0.12 Nm
Section D

3N 530mm 3N 3N

V M
X
350mm 3N

M x =3 x −3(x −0.22)−3(x −0.35)+3(x −0.530)

M 0.53=0.12 Nm
M 0.55=0.12 Nm
Section E

3N 530mm 3N 3N

V M
X
550mm 3N 3N

M x =3 x −3(x −0.22)−3(x −0.35)+3(x −0.530)−3(x −0.55)

M 0.55=0.12 Nm
M 0.7=0.57 Nm
 M X (MAX )=0 .66 Nm
M Y (MAX )=4.1 Nm
τ (MAX )=8.0 Nm

M (MAX )=√ 0.662 +4.12

M (MAX )=4.2 Nm

1 1 1
16 n 1 1
di min =( ( ( 4 M 2a ) 2 + (3 T 2m ) 2 )) 3
N Se Sy
¿ 28 mm

The system is safe with shaft of diameter of 30mm

BEARING SELECTION

2.5 PRODUCT FILLING

The filling system then dispenses the product into the formed tube. The choice of
filling mechanism depends on the product's characteristics and the desired packaging
precision, with volumetric cup fillers and auger fillers being common examples.

FILLING METHODS
Vertical form fill and seal (VFFS) machines utilize various product filling methods to
accurately dispense products into packaging. Here are some common product filling
methods used in VFFS machines:

 Auger Filling System: This system uses a rotating auger screw to measure and
dispense powdered or granular products into the packaging material. It's suitable
for products like flour, spices, coffee powder, etc.

 Volumetric Cup Filling System: Volumetric cup fillers use cups of

predetermined volume to measure and dispense products into the packaging
 material. They're commonly used for granular or free-flowing products like rice,
beans, candies, etc.

 Hopper Conveyor System :This system uses a simple conveyor belt feeding into
a hopper . The conveyor is the one that is used to adjust feed rates .

 Liquid Pump Filling System: This system utilizes a liquid pump to accurately
measure and dispense liquids such as oils, sauces, juices, etc., into the packaging
material. It ensures precise filling levels and minimizes spillage.

 Weighing Scale Filling System: Weighing scales integrated with the VFFS
machine can measure the weight of the product before dispensing it into the
packaging material. This system is versatile and can handle various types of
products, including granular, powdered, and liquid.

 Multi-Head Weigher Filling System: Multi-Head weigher consist of multiple

weighing buckets that simultaneously measure and dispense products into the
packaging material. They're often used for products like snacks, candies, nuts,
etc., providing high-speed and accurate filling.

 Piston Filling System: Piston fillers use a piston mechanism to measure and
dispense viscous or semi-viscous products such as creams, pastes, gels, etc., into
the packaging material. They ensure precise filling and are suitable for products
with varying viscosities.

 Vacuum Filling System: Vacuum fillers are used for filling powders or granules
into the packaging material under vacuum conditions. This system helps in
removing air from the package, preserving product freshness and extending shelf
life.
Choose Hopper conveyor system for their simplicity, reliability, and suitability for
filling granular or free-flowing products consistently.

KEY COMPONENTS OF HOPPER CONVEYOR SYSTEM

Key components of Hopper Conveyor System, which are commonly used in vertical
form fill and seal (VFFS) machines and other packaging systems, include:

 Hopper: The hopper is the reservoir where the product is stored before being
dispensed. It ensures a continuous supply of product to the filling mechanism.

 Dosing Chamber: The dosing chamber holds the predetermined volume of

product to be dispensed into each package. It is often adjustable to accommodate
different fill volumes.

 Discharge Nozzle: The discharge nozzle directs the product from the dosing
chamber into the packaging. It may include features such as valves or seals to
ensure precise control over the product flow.
 Frame and Support Structure: The frame and support structure provide stability
and support for the various components, ensuring accurate and reliable operation.

CONVEYOR CALCULATIONS

Conveyor length=2
Conveyor width=0.5
Transfered load=50 kg

MASS CALCULATIONS
material=PVC + Polyester Canvas
unit mass=2.3 kg per area
thickness=2.1 mm
area=2× 2× 0.5
mass=2.1 ×5
mass=11.5kg
total mass=61.5 kg

POWER CALCULATIONS
Linear speed=0.2m/ s
Power=Force× Velocity
Pull Force=Friction Force
Friction Force=μ N
Force=0.2 × 61.5× 9.81
Force=121 N
Power=121× 0.2
Power=24.2 Watts
SF=1.5
Power=36.3 Watts

RPM CALCULATIONS
Roller Diameter =30 mm
linear length=π ×0.3
Rpm=π × 0.3 ×0.2 ×60

Rpm=11.4

MOTOR REQUIRED
RPM =12
Power=40 Watts
2.7 DISCHARGE
Finally, the completed bags are discharged from the machine, poised for further processing or
packaging.

KEY COMPONENTS

 Discharge Conveyor: The discharge conveyor transports filled and sealed bags away from the
VFFS machine for further processing or packaging. It typically consists of a belt or roller system
that moves the bags smoothly and efficiently.

 Bag Support: Bag support mechanisms ensure that filled bags are properly supported and guided
as they move along the discharge conveyor, preventing them from tipping over or becoming
misaligned.
 CONVEYOR CALCULATIONS

Conveyor length=2
Conveyor width=0.5
Transfered load=50 kg

MASS CALCULATIONS

material=PVC + Polyester Canvas

unit mass=2.3 kg per area
thickness=2.1 mm

area=2× 2× 0.5
mass=2.1 ×5
mass=11.5kg
total mass=61.5 kg

POWER CALCULATIONS

Linear speed=0.2m/ s
Power=Force× Velocity
Pull Force=Friction Force
Friction Force=μ N
Force=0.2 × 61.5× 9.81
Force=121 N
Power=121× 0.2

Power=24.2 Watts
SF=1.5
Power=36.3 Watts

RPM CALCULATIONS

Roller Diameter =30 mm

linear length=π ×0.3
Rpm=π × 0.3 ×0.2 ×60

Rpm=11.4

MOTOR REQUIRED
RPM =12
Power=40 Watts