VFFS - Customised Shaping

The Nexus ESP-4 shaped pouch VFFS machine forms, fills and seals sachets from roll film, then cuts each one to a custom outline. It runs four lanes side by side and suits liquid and cream products in small single-dose packs, such as cosmetic samples, lotions, serums, gels and sauces. Nexus Australia supplies and supports it Australia-wide.

Also known as a shaped sachet machine, a shape pouch packing machine, a custom shape sachet machine or a die-cut sachet machine.

How the shaped pouch VFFS works

• Film feed: printed film unwinds from the main roll and is guided down into the four lanes. A date coder can be fitted on the film path as an option.
• First sealing and filling: the first set of seal jaws forms each lane into a pocket, and the filling pumps dose product into it.
• Final shaping seal: a shaped seal die closes the sachet along the custom outline, so the seal follows the shape of the finished pack.
• Trimming and dispensing: a cutting die trims each sachet out along the shaped seal and drops the finished packs onto the outfeed conveyor.
• Waste spool: the trimmed film skeleton left after cutting is wound onto a waste spool, which keeps the machine clean and the line running.

Why choose a shaped sachet

A shaped sachet stands out on a shelf, in a magazine insert or in a gift pack, where a plain rectangle does not. The outline can follow a bottle, a leaf, a drop or a brand mark, and a tear notch can be placed where the user expects it. For brands sending out samples, the shape does part of the marketing work before the pack is opened.

Products and industries

Cosmetics and skincare are the main users: lotion, moisturiser, serum, toner, shampoo, conditioner and hair treatments in trial sizes. The same machine also packs food liquids and sauces, honey, gels, and pharmaceutical or nutraceutical liquids in single doses. Pump dosing suits thin liquids through to creams.

Shaped sachets versus standard sachets

A standard sachet packing machine makes rectangular three-side or four-side seal sachets, which gives the lowest cost per pack for high-volume portions. The shaped pouch VFFS adds a shaped seal and a cutting die, so each format needs its own tooling, but the finished pack looks premium. If you need narrow tube-shaped packs, see the stick pack machine. For larger bags, see the standard VFFS machine.

Lead time, installation and after-sales support

Allow about 75 days from order to shipment for a standard machine, and 90 to 120 days for a complex application, plus freight and installation. Shaped tooling is made to your sachet design, so send us the outline and fill volume early. Every machine is quoted individually.

Installation and commissioning are done by Nexus technicians in every state and territory. Support after the sale covers operator training, preventive maintenance, spare parts and technical help by phone or video call. Common spares are stocked in Australia, and the warranty is 12 months return-to-base, excluding wear parts. Nexus Australia is a member of APPMA, the Australian Packaging and Processing Machinery Association.

Related: VFFS machines, sachet packing machines, stick pack machines and the full bagging system range. Send us your sachet shape, fill volume and product and we will specify the machine. Contact Nexus Australia for a quote on a shaped sachet VFFS machine.