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International Journal of Science, Strategic Management and Technology

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DESIGN AND DEVELOPMENT OF AN INDUSTRIAL FORM-FILL-SEAL (FFS) PACKAGING MACHINE

AUTHORS:
Kartik Yogesh Pachpol
Shruti Vijay Kadam
Pratiksha Nana Girme
Mentor
Prof. V. B. Baru
Affiliation
Dept. of Electronics and Telecommunication Sinhgad College of Engineering Pune, India
DOI: 10.55041/ijsmt.v2i6.162
CC BY 4.0 License:
This article is an open access article distributed under the terms and conditions of the Creative Commons Attribution (CC BY) license, which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited.
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Abstract
Form-Fill-Seal (FFS) machines are widely used in packaging industries to automate the processes of forming, filling, sealing, and cutting packages. However, industrial FFS machines are costly, mechanically complex, and not suitable for classroom demonstrations or introductory training in automation systems. To address this limitation, a compact PLC-HMI based FFS demonstration platform was developed to represent the operating sequence of an industrial packaging machine in a safe and simplified manner.

The developed system uses a B&R Power Panel C50 integrated controller and Human-Machine Interface (HMI) operating on a 24 V DC supply. Sixteen toggle switches are used to simulate machine inputs, while sixteen LED indicators represent machine outputs such as film feeding, filling, sealing, cutting, and alarm conditions. The control sequence was implemented using PLC logic and tested under different operating conditions to verify correct system behaviour.

Experimental testing confirmed reliable execution of the programmed sequence and proper response to start, stop, and emergency commands. The developed platform provides a practical way to demonstrate industrial automation concepts, PLC programming, HMI operation, and machine-sequence control without the safety risks and cost associated with a full-scale packaging machine
Keywords
Form-Fill-Seal PLC HMI packaging automation industrial control ladder logic.
Article Information
PUBLICATION DETAILS
Review Type:
Double-Blind Peer Review
License:
CC BY-NC 4.0
Volume/Issue:
Volume 02, Issue 6
Review Rounds:
2
Article Type:
Research Article
Publication Date:
Jun 20 2026
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Pachpol, K. Y., Kadam, S. V. & Girme, P. N. (2026). Design and Development of an Industrial Form-Fill-Seal (FFS) Packaging Machine. International Journal of Science, Strategic Management and Technology, 02(6). https://doi.org/10.55041/ijsmt.v2i6.162

Pachpol, Kartik, et al.. "Design and Development of an Industrial Form-Fill-Seal (FFS) Packaging Machine." International Journal of Science, Strategic Management and Technology, vol. 02, no. 6, 2026, pp. . doi:https://doi.org/10.55041/ijsmt.v2i6.162.

Pachpol, Kartik,Shruti Kadam, and Pratiksha Girme. "Design and Development of an Industrial Form-Fill-Seal (FFS) Packaging Machine." International Journal of Science, Strategic Management and Technology 02, no. 6 (2026). https://doi.org/https://doi.org/10.55041/ijsmt.v2i6.162.

References

  1. Viking Masek, “A guide to vertical form fill seal machines,” Viking Masek Packaging Technologies. [Online]. Available: https://vikingmasek.com/blog/a-guide-to-vertical-form-fill-seal-machines

  2. Merabtene, P. Tanninen, J. Varis, and V. Leminen, “Heat sealing evaluation and runnability issues of flexible paper materials in a vertical form fill seal packaging machine,” BioResources, vol. 17, no. 1, pp. 223–242, 2022, doi: 10.15376/biores.17.1.223-242.

  3. Merabtene, A. Pesonen, P. Tanninen, J. Varis, and V. Leminen, “Novel forming shoulder for coated paper-based materials with improved convertibility and minimum wrinkles for use in vertical form, fill and seal machines,” Packaging Technology and Science, vol. 38, pp. 131–143, 2025, doi: 10.1002/pts.2862.

  4. Sachin M. and Sree Rajendra, "Efficiency Optimization of Continuous Motion Vertical Form Fill and Seal Machine," International Research Journal of Engineering and Technology (IRJET), vol. 8, no. 8, pp. 1118-1121, Aug. 2021.

  5. A. Algitta, M. Suad, F. Ibrahim, N. Abdalruof, and M. Yousef, “Automated packaging machine using PLC,” Int. J. Innov. Sci. Eng. Technol. (IJISET), vol. 2, no. 5, May 2015.

  6. Bhanwrela, J. Managre, N. Purohit, and N. Gupta, "To Integrate and Optimize the Use of Programmable Logic Controller in Development of Horizontal Flow Wrap Packaging Machinery for Industry Needs," Journal of Sustainable Development Innovations, vol. 1, no. 4, pp. 158-165, 2024, doi: 10.61552/JSI.2024.04.004.

  7. Z. Ur Rahman, M. S. Shabbir, M. Hassan, M. u. Hassan, H. Ahmad and A. Waleed, "Stepper-based Precise Paper Cutting Machine with PLC and HMI," 2024 Horizons of Information Technology and Engineering (HITE), Lahore, Pakistan, 2024,1-7, doi: 10.1109/HITE63532.2024.10777152.

  8. B. Mofidul, M. S. H. Sabbir, A. K. Podder and M. Shaifur Rahman, "Design and Implementation of Remote Controlling and Monitoring System for Automatic PLC Based Packaging Industry," 2019 1st International Conference on Advances in Science, Engineering and Robotics Technology (ICASERT), Dhaka, Bangladesh, 2019, pp. 1-5, doi: 10.1109/ICASERT.2019.8934779.

  9. P. Kshirsagar et al., “Automatic sorting machine using PLC and HMI technique,” Int. J. Recent Innov. Trends Comput. Commun. (IJRITCC), vol. 11, no. 10, pp. 678–683, 2023, doi: 10.17762/ijritcc.v11i10.8563.

  10. D. Petruzella, Programmable Logic Controllers, 6th ed. New York, NY, USA: McGraw-Hill, 2023.

Ethics and Compliance
✓ All ethical standards met
This article has undergone plagiarism screening and double-blind peer review. Editorial policies have been followed. Authors retain copyright under CC BY-NC 4.0 license. The research complies with ethical standards and institutional guidelines.
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