Flow Wrapping: Secondary Packaging for Maximum Product Protection
Last updated: 02. March 2026
Flow wrapping is an automated packaging process, also known as tubular bag packaging or Horizontal Form Fill Seal (HFFS). The principle: products are continuously wrapped in a flat-fed film web, which is formed into a tube. In a straight line, a wide variety of articles can thus be efficiently sealed and welded in plastic film.
The term originates from English ("flow" and "wrapping") and describes the fluid, continuous process for which the technology is known worldwide. The process was shaped, among others, by pioneers such as Samuel John Campbell, who developed one of the first advanced wrapping machines for plastic films.
What exactly happens during flow wrapping?
- Step 1: The articles are guided into the packaging zone at precise intervals on a feed belt.
- Step 2: The machine automatically unwinds a film web. In the pharmaceutical industry, specialized multi-layer composite films (laminates) are mostly used here to guarantee optimal barrier properties.
- Step 3: The film is placed around the product into a tube via a forming shoulder.
- Step 4: The sealing of the longitudinal seam is carried out continuously by heated sealing rollers. Here, the film is precisely welded so that a defined longitudinal seal (fin seal) is created, which protects the product.
- Step 5: Finally, the ends of the tube are sealed by sealing jaws and the packages are separated from each other by precise, synchronized cutting stations.
Flow Wrapping: Performance and Speed
The output of an HFFS system is directly dependent on the product geometry and the film properties. While compact systems for smaller batches cover the range of 50 to 200 cycles per minute, specialized high-speed systems in combination with Blow-Fill-Seal lines achieve outputs of up to 1,000 units per minute.
Where are flow wrapping machines used?
In Medicine and Pharmacy: In the pharmaceutical sector, flow wrapping often serves as secondary packaging (overwrap). While the Blow-Fill-Seal process (BFS) guarantees the aseptic filling of the product in the primary container, the additional tubular bag packaging protects the container from external influences, minimizes water vapor permeation, and ensures integrity during transport.
In Cosmetics: For cosmetic products without preservatives, maximum protection is essential. Rommelag combines the advantages of the hermetically sealed BFS containers with a robust tubular bag overpackaging to maximize product shelf life even under demanding environmental conditions.
In Chemistry: In chemistry as well, liquid specialty chemicals in BFS containers are additionally protected from environmental influences by flow wrapping. Furthermore, the technology is used for solid chemical substances or tabs with a water-soluble shell.
Which materials are best suited?
- Polypropylene (PP): Valued in the pharmaceutical sector for its high transparency and temperature resistance, making it ideal for products that must be sterilized after packaging.
- Polyethylene (PE): Impresses with excellent sealing properties and flexibility, enabling a particularly secure seam guidance.
- Film laminates (laminates): These often contain barrier layers (e.g., aluminum) to consistently keep light, moisture, and oxygen away from the product – a must for sensitive pharmaceuticals.