SUSTAINABLE VFFS POWDER & GRANULES PACKAGING MACHINE

International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056

Volume: 13 Issue: 04 | Apr 2026 www.irjet.net p-ISSN: 2395-0072

SUSTAINABLE VFFS POWDER & GRANULES PACKAGING MACHINE

Mr. Jafri Md. Khaja Saifuddin1 , Prof. Vijay D. Kolate 2 , Prof. Vishnu B. Ghagare 3 , Mr. Shakil R. Shaikh4

1M.E.Student,Dept.ofMech.Engineering,KJEI'sTrinityCollegeofEngineeringandResearch,Pune, Maharashtra,India

2 AssistantProfessorDept.ofMech.Engg.,KJEI'sTrinityAcademyofEngineering,Pune,Maharashtra,India

3 AssociateProfessorDept.ofMech.Engg.,KJEI'sTrinityCollegeofEngineeringandResearch,Pune, Maharashtra,India

4 Lecturer,Dept.ofMechanicalEngineering,ZES'sZealPolytechnic,Pune,Maharashtra,India ***

Abstract - Sustainability and operational efficiency have become critical priorities in modern packaging industries, particularly in the handling of powders and granules.

Conventional Vertical Form Fill Seal (VFFS) packaging machines often face challenges related to material wastage, high energy consumption, dust emission, and inconsistent filling accuracy. This study presents a Sustainable VFFS Powder & Granules Packaging Machine integrating energyefficientdrivesystems,optimizedsealingmechanisms,andan advanced controlled dosing unit to enhance performance whileminimizingenvironmentalimpact.

The proposed system incorporates a precision filling mechanism combined with intelligent control algorithms to ensure accurate weight control and reduced product loss. Additionally,thedesignemphasizesreducedfilmconsumption through optimized bag forming geometry and improved sealing efficiency, leading to lower material waste. Energysaving components and modular construction further contribute to reduced operational costs and enhanced maintainability.

Thissystemimprovedfillingaccuracy,speed, stablemachine performance with leakproof pouches and lower power consumption compared to conventional VFFS systems. The integration of sustainable design principles with high-speed automated packaging provides a practical solution for industries seeking eco-friendly, cost-effective, and highperformance powder and granule packaging. Future work may explore IoT-enabled monitoring and AI-based adaptive control to further optimize system efficiency and sustainability.

Keywords: Sustainable Packaging, VFFS Machine, Powder Filling, Granule Packaging, Energy Efficiency, Waste Reduction,Eco-FriendlyAutomation.

1. Overview of Auger Filling Systems

Augerfillingsystemsareextensivelyusedinindustriesthat require precise, consistent, and efficient dispensing of powders and granules. These systems operate using a rotatinghelicalscrewmechanism,knownasanauger,which conveys productfroma hopperintocontainersorflexible

packaging. Auger fillers are valued for their adaptability, highaccuracy,andabilitytohandleawiderangeofmaterials including free-flowing powders, semi-cohesive materials, finedust-likesubstances,andcertaingranularproducts.

Theworkingprincipleofanaugerfillerisprimarilybasedon volumetricdosing,wherethequantityofmaterialdispensed is controlled by adjusting the number of auger rotations. Eachrotationdeliversapredeterminedvolumeofproduct. For higher precision requirements, advanced systems incorporate load cells or check-weighing feedback mechanisms to ensure accurate weight-based dosing and minimizeproductgiveaway.

Modern auger filling systems are often integrated with automatedpackaginglinestoenhanceproductivity,reduce manual handling, and maintain hygiene standards. Their controlleddispensingcapabilitymakesthemhighlysuitable forsustainableandhigh-speedpackagingoperations.

1.1 Introduction to VFFS Bagger (Vertical Form Fill Seal Machine)

A Vertical Form Fill Seal (VFFS) machine is an automated packaging system widely used for forming, filling, and sealingflexiblepouchesinasinglecontinuousprocess.The machineforms bagsfroma flatroll of packagingfilm, fills them with product (powder or granules), and seals them verticallyandhorizontallytocreatefinishedpackages.

In powder and granule packaging applications, the VFFS machine is commonly integrated with auger fillers or volumetriccupfillerstoensureaccurateproductdosing.The packagingprocessinvolvesthreemainstages:

Forming–Thefilmrollisshapedintoatubeusingaforming collar.

Filling – The product is dispensed into the formed tube throughthefillingsystem.

International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056

Volume: 13 Issue: 04 | Apr 2026 www.irjet.net p-ISSN: 2395-0072

Sealing & Cutting – The vertical and horizontal seals are applied,andindividualpouchesarecut.

VFFS baggers are known for their high production speed, compactfootprint,costefficiency,andsuitabilityforawide range of packaging materials. They support sustainable packaging initiatives by optimizing film usage, reducing waste,andenablingtheuseofrecyclableorbiodegradable materials.

1.2. Integration of Auger Filling System with VFFS Machine

TheintegrationofaugerfillingsystemswithVFFSbaggers createsahighlyefficientandautomatedsolutionforpowder and granule packaging. The auger filler ensures precise productmeasurement,whiletheVFFSsystemprovidesrapid bagformationandsealing.Thiscombinationenhancesfilling accuracy,reducesmaterialloss,minimizesdustemission,and improvesoverallpackagingefficiency.

Such integrated systems are increasingly developed with energy-efficientmotors,servo-drivencontrols,andintelligent automationfeaturestopromotesustainableandeco-friendly packagingoperations.

2. Literature Review

Acomprehensivereviewofpreviousstudiesonaugerfilling systems, vacuum assistance, and variable screw pitch is essential to understand existing challenges and highlight researchgaps.Thissectionexploreskeyfindingsfrompast researchandjustifiestheneedforthisstudy.

2.1 Auger Filling Systems and Accuracy Challenges

Auger fillers have been extensively studied for their precision,efficiency,andadaptabilityacrossindustries.Most research focuses on volumetric and gravimetric filling approaches:

Volumetric Auger Fillers – Powder is dosed based on the volumedisplacedbytheaugerrotation.However,variations inpowder density,humidity,andparticlesizecauseinconsistenciesin weight.(Source:Singh&Patel,2020)

GravimetricAugerFillers–Usereal-timeweightfeedbackfor higher accuracy but require additional sensors, increasing systemcomplexity.(Source:Zhangetal.,2019)

Despite advancements, auger fillers still face accuracy limitations,particularlywhendealingwith: Fine,cohesivepowders(e.g.,milkpowder,proteinpowders) thatformclumps.

Electrostatic powders that stick to equipment surfaces, causingdosingerrors.

Non-uniformpowderflow,leadingtoweightdeviations.

2.2 Impact of Screw Design on Powder Flow & Accuracy

Theaugerscrewdesignsignificantlyinfluencesmaterialflow consistency,accuracy,andspeed.Researchhighlights:

Fixed-Pitch Augers – Maintain uniform spacing between flights but struggle with powders that compact or aerate unpredictably.(Source:Kimetal.,2021)

Variable-Pitch Augers – Can improve powder flow by graduallychangingpitchtocontrolcompactionandaeration, enhancingaccuracy.(Source:Gupta&Rao,2018)

However, no study has optimized the combination of variable-pitch screws and vacuum assistance to enhance dosingperformance.

2.3 Vacuum Assistance in Powder Handling

Vacuumsystemshavebeenexploredforimprovingpowder flow, reducing dust emissions, and enhancing dosing precision:

Vacuum-Assisted Powder Conveying – Used in pharmaceuticalandfoodindustriestostabilizebulkdensity andimproveflow.(Source:Jonesetal.,2022)

DustReduction via VacuumSystems – Studiesshowa 30–50% reduction in airborne dust when vacuum-assisted containmentisapplied.(Source:Müller&Schwarz,2020) Althoughvacuumassistancehasbeenproveneffective,there isnoresearchintegratingitwithvariable-pitchaugersina fillingsystem.

3. Research Gaps & Justification for This Study

I. LimitedresearchonSustainableVFFSPowder&Granules PackagingMachine

II. Nostudiesonsustainablerecyclingflexiblefilm laminates.

4. Research Objectives

Theprimaryobjectiveofthisresearchistodesign,develop, and evaluate a Sustainable Vertical Form Fill Seal (VFFS) Powder & Granules Packaging Machine that enhances packagingefficiencywhileminimizingenvironmentalimpact. The study aims to address key challenges in conventional VFFS systems, such as material wastage, high energy consumption,dustemission,andinconsistentfillingaccuracy, byintegratingenergy-efficientcomponents,optimizedfilm utilization,andprecisiondosingmechanisms.

International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056

Volume: 13 Issue: 04 | Apr 2026 www.irjet.net p-ISSN: 2395-0072

4.1 Specific Objectives:

1. To analyze the performance of an optimized filling mechanism (auger/volumetric system) in improving powder and granule dosing accuracy while reducing productloss.

2. To investigate methods for minimizing packaging materialwastethroughimprovedformingcollardesign andoptimizedbaggeometry.

3. To evaluate the impact of energy-efficient drive systems(servomotorsandcontrolledsealingsystems) onoverallpowerconsumptionreduction.

4. Toassesstheeffectivenessofdustcontrolandsealing enhancements in improving hygiene and reducing airbornecontaminationduringpackaging.

5. To compare the proposed sustainable VFFS system withconventionalVFFSmachinesintermsofenergy usage, material utilization, filling accuracy, and productionthroughput.

6. To optimize the integration of intelligent control systems for real-time monitoring and adaptive adjustments to enhance operational efficiency and sustainability.

7. To develop an eco-friendly, high-speed, and costeffective packaging solution suitable for food, pharmaceutical, chemical, and industrial powder applications.

5. Research Methodology

5.1 Study of existing auger filling system parameters & its results

Powderstoredinthehopperisfedintotheaugertooling.The toolingconsistsofanauger,anagitatorblade,andafunnel. Two motors mountedatopthe filler offerseparateprecise controlovertherotationoftheaugerandtheagitatorblade.

Theaugerrotatestomovetheproductdowntothefunnel, while the agitator blade works to prevent any product buildupsorleftoversinthehopper.

Further,theagitatorbladeisdesignedtogoallthewaydown tothefunnel.Thisensuresthattheaugerflightsarealways packedwiththeproducts.

The auger flights are spaced at the same distance. This ensuresthateachflightingpitchisfilledwithingredientsof the same bulk density and particle size. It helps achieve precisedosingastheaugerrotates.

5.2 Study conducted on regular auger filling system

AugerScrewSpecificationsintheinitialphaseofthestudy,an augerscrewwiththefollowingspecificationswasselectedfor performanceevaluation:

 ScrewDiameter:67mm

 ScrewPitch:67mm(1:1ratioofdiameter topitch)

 ProductUsed–Flour(Atta).

This configuration was chosen to establish a baseline for doingaccuracyandfillingspeedbeforeintroducingvariable pitchandvacuumassistance.

5.3 Experimental Procedure

Theaugerfillingsystemwastestedunderstandardoperating conditionstoevaluate:

WeightAccuracy:Thedeviationofactualfilledweightfrom thetargetweight(1kg).

International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056

Volume: 13 Issue: 04 | Apr 2026 www.irjet.net p-ISSN: 2395-0072

MACHINE SPEED & SCREW CALCULATION

Screw Data:

 Actual we were getting =183.6 cc. Means we are gettingactual–91.8gminsteadoftheoretical108 gm. 15 % less weight we are getting after several iterationsitvaries15to20%.

International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056

Volume: 13 Issue: 04 | Apr 2026 www.irjet.net p-ISSN: 2395-0072

Initial Conclusion – We are not getting 100% fill pitch resultinglowweightdosingineachpitch,whichresultslow speed,weightvariation&rejection.

Bagger speed at 55-60 ppm for 1 kg of powder or flour has been enhanced with modified auger and recyclable film

International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056

Volume: 13 Issue: 04 | Apr 2026 www.irjet.net p-ISSN: 2395-0072

 Reduced energy consumption through servocontrolleddrives

 Enhanced production throughput without compromisingquality

Theintegrationofvacuum-assisteddustextractionstabilized powderflow,minimizedproductaeration,andimprovedthe cleanliness of the packaging environment. Additionally, optimized formingandsealing mechanismscontributedto reducedmaterialwasteandimprovedsealintegrity.

Withthesetupwegettheweightaccuracyof+/-6gmfor1 kgwith590.18msecfillingtimewithpossiblespeedof55-60 BPM

Conclusionsectionrewrittenand aligned with yourtopic: Conclusion

From the experimental evaluation of the proposed SustainableVFFSPowder&GranulesPackagingMachine,itis evidentthattheintegrationofenergy-efficientcomponents, optimized filling mechanisms, and dust-control systems significantly enhances overall packaging performance and sustainability.

The baseline conventional VFFS system demonstrated moderatefillingaccuracywithnoticeableproductloss,higher energyconsumption,andmeasurabledustemissionsduring powderhandling.Uponimplementinganoptimizedprecision filling mechanism and improved bag-forming design, the system showed a measurable improvement in fill weight consistencyandreductioninmaterialwastage.Furthermore, when the optimized filling system was combined with an integrated vacuum-assisted dust control unit and energyefficient servo-driven sealing mechanisms, the machine exhibitedsubstantialimprovementsinoperationalefficiency, hygienecontrol,andpowerconsumptionreduction.

Theresultsindicatethatthesustainablemodificationsledto:

 Improved filling accuracy and reduced weight variation

 Significant reduction in airborne dust emissions duringthefillingcycle

 Lowerpackagingfilmconsumptionduetooptimized baggeometry

This study clearly demonstrates that the proposed sustainableVFFSsystemprovidesapracticalandeco-friendly solution for industries handling powders and granules, particularlyinfood,pharmaceutical,chemical,andindustrial applications. By combining precision dosing, energy efficiency, and waste reduction strategies, the machine supportsmodernsustainabilitygoalswhilemaintaininghighspeedproductionrequirements.

Future research may focus on:

AdvancedIoT-basedreal-timeenergymonitoringsystems

AI-driven adaptive filling control for different powder characteristics

Development of biodegradable and recyclable film compatibility

Further optimization of vacuum intensity and sealing temperatureprofiles

Overall,theSustainableVFFSPowder&GranulesPackaging Machine represents a significant advancement toward environmentallyresponsible,high-performanceautomated packagingsystems.

REFERENCES

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[2]J. Clayton, “Reviewing Current Practice in Powder Testing,” Apr. 15, 2014, American Chemical Society. doi: 10.1021/op500019m.

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[5]Sumeth Singphu, Sombat Teekasap, Supawadee Theerathammakorn-Fillingimprovementofthefacepowder

International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056

Volume: 13 Issue: 04 | Apr 2026 www.irjet.net p-ISSN: 2395-0072

with auger filler machine To reduce the variability of the fillingweight.

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[6]El Kassem, Bilal. Machine design for auger dosing of powders by utilizing DEM simulations and multivariateregression-based experimental analysis. Diss. UniversitätsbibliothekderRWTHAachen,2021.

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[8]"Design and Development of a Mechanized Auger for Cassava Mash" Authors:A.A.Adetunji,O.A.Raji,andK. A. Olaoye

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BIOGRAPHIES

M.E.Student Dept.ofMechanicalEngineering

KJEI's Trinity College of EngineeringandResearch, Pune,Maharashtra,India

AssistantProfessor Prof.VijayD.Kolate Dept.ofMechanicalEngineering

KJ's Education Institutes Trinity Academy of Engineering, Pune, Maharashtra,India

AssociateProfessor Dept.ofMechanicalEngineering

KJEI's Trinity College of EngineeringandResearch, Pune,Maharashtra,India

Lecturer, Dept. of Mechanical Engineering, ZES's Zeal Polytechnic, Pune, Maharashtra,India.