Understanding Flow Wrap and Overwrap
In the packaging industry, two common methods used to package products are flow wrap and overwrap. Both techniques are employed to protect products, enhance their shelf life, and improve their presentation. However, they differ in terms of application, materials used, and the type of products they are best suited for. Understanding these differences can help businesses choose the most appropriate packaging solution for their products.
What is Flow Wrap?
Flow wrap, also known as horizontal form-fill-seal (HFFS), is a packaging process that wraps a product in a single continuous piece of film. This film is typically heat-sealed at the ends and along the back to create a tight, protective enclosure around the product. The flow wrap process is highly automated and involves the following steps:
1. Film Feeding
A roll of film is fed into the flow wrapping machine, which unwinds the film and positions it to wrap around the product. The film can be made from various materials, including polyethylene, polypropylene, or other laminates, depending on the product’s requirements.
2. Product Insertion
The product is placed onto the film, either manually or automatically, as it moves along a conveyor belt. The film is then wrapped around the product, forming a tube-like structure.
3. Sealing
The film is sealed along the back and at both ends using heat or pressure. This creates a hermetic seal that protects the product from external contaminants and moisture.
4. Cutting
Finally, the wrapped product is cut from the continuous film, completing the packaging process. The result is a neatly wrapped product that is ready for distribution or sale.
Applications of Flow Wrap
Flow wrap is widely used in the food industry for packaging items such as candy bars, biscuits, baked goods, and fresh produce. It is also used for non-food items like medical supplies, hardware, and consumer goods. The main advantages of flow wrap include its speed, efficiency, and ability to accommodate high-volume production. Additionally, flow wrap provides excellent protection and can be customized with branding and product information.
What is Overwrap?
Overwrap, on the other hand, is a packaging technique that involves wrapping a product or a group of products with a film or paper. Unlike flow wrap, overwrap is not a continuous process and often involves wrapping individual items or bundles. The overwrap process typically includes the following steps:
1. Film or Paper Selection
Overwrap can be done using various materials, including cellophane, polypropylene, or paper. The choice of material depends on the product’s requirements, such as the need for breathability, moisture resistance, or aesthetics.
2. Product Arrangement
Products are arranged in a specific configuration, either individually or in groups, before being wrapped. This step is crucial for ensuring that the overwrap provides adequate protection and presentation.
3. Wrapping
The selected film or paper is wrapped around the product or group of products. This can be done manually or using automated machinery, depending on the scale of production.
4. Sealing
The overwrap is sealed using heat, pressure, or adhesive, depending on the material used. This step ensures that the wrap stays in place and provides a protective barrier.
Applications of Overwrap
Overwrap is commonly used for packaging items such as cigarette packs, DVD cases, and gift boxes. It is also used for bundling multiple products together, such as multipacks of beverages or toiletries. The main advantages of overwrap include its versatility, ability to enhance product presentation, and potential for branding. Overwrap can also be used to provide tamper-evidence and improve the shelf life of products by protecting them from moisture and contaminants.
Key Differences Between Flow Wrap and Overwrap
While both flow wrap and overwrap serve the purpose of packaging products, they differ in several key aspects:
1. Process
Flow wrap is a continuous, automated process that is ideal for high-volume production. In contrast, overwrap can be either manual or automated and is suitable for both individual items and groups of products.
2. Materials
Flow wrap typically uses flexible films like polyethylene or polypropylene, while overwrap can use a wider range of materials, including cellophane, paper, and more rigid films.
3. Applications
Flow wrap is commonly used for individual food items and small consumer goods, whereas overwrap is often used for packaging larger items, bundles, or products that require enhanced presentation.
4. Sealing
Flow wrap involves heat sealing along the back and ends, creating a hermetic seal. Overwrap may use heat, pressure, or adhesive for sealing, depending on the material and application.
Conclusion
In summary, both flow wrap and overwrap are valuable packaging techniques with distinct advantages and applications. The choice between the two depends on factors such as the type of product, production volume, desired presentation, and specific packaging requirements. By understanding the differences between flow wrap and overwrap, businesses can make informed decisions to optimize their packaging processes and meet their product protection and presentation goals.
