Flexible Package Manufacturing – Pouch Formation and Sealing

Abstract

This chapter examines pouch forming mechanisms and seal technologies for flexible packaging applications. It discusses key stages in vertical and horizontal form-fill-seal (FFS) systems. The principles of heat-conductive sealing and ultrasonic sealing are compared, and other seal technologies are briefly outlined. The concept of caulkability is introduced as a critical factor in achieving seal integrity and reliable seal-through performance. An overview of thermoplastic seal polymers, barrier materials, substrates and mono-material solutions is provided, along with considerations for recycled content and its impact on seal properties. The chapter concludes by addressing recent advancements in seal equipment and process adaptations that enable high seal quality while supporting circular packaging systems.