10 Common Packaging Machine Problems (and How to Fix Them)
In food manufacturing, packaging machinery downtime can quickly lead to lost output, delayed orders, increased waste, and unnecessary pressure on production teams. Whether you operate a vertical form fill seal system, tray sealer, flow wrapper, checkweigher, vacuum packer, or a complete automated line, even minor faults can disrupt efficiency. We also provide servicing support to help keep your equipment running smoothly - book a service here.
The good news is that many common packaging machine problems can be identified and resolved quickly with the right checks and routine maintenance.
At The Food Machinery Company, we supply and support reliable food packaging machinery for manufacturers across the UK. Below are 10 common packaging machine issues, their likely causes, and practical ways to fix them.
1. Poor Seal Quality or Leaking Packs
Weak or inconsistent seals can lead to reduced shelf life, contamination risks, and rejected stock, particularly in pouch filling machinery.
Common Causes:
Incorrect sealing temperature
Insufficient dwell time
Low sealing pressure
Product trapped in the seal area
Damaged or contaminated sealing jaws
Incorrect film material
How to Fix It:
Check temperature settings, clean seal jaws, inspect for wear, and adjust fill timing if product is entering the seal area.
2. Film Tracking Problems
Common Causes:
Misaligned film reel
Uneven film tension
Misaligned pulling belts
Worn belts
Jammed rollers
Incorrect forming collar setup
How to Fix It:
Re-centre the reel, clean rollers, inspect belts, and ensure the forming collar is aligned.
3. Inconsistent Pack or Bag Lengths
Common Causes:
Slipping pull belts
Faulty sensor
Incorrect encoder settings
Film tension fluctuations
How to Fix It:
Clean or replace belts, recalibrate sensors, and confirm encoder settings. Accurate weighing systems such as multihead weighers can also improve consistency.
4. Product Trapped in the Seal
Common Causes:
Poor timing
Overfilling
Fast speeds
Contamination
How to Fix It:
Adjust timing, reduce fill, and increase cleaning frequency. Proper upstream handling using conveyor systems can help regulate product flow.
5. Cutting Knife Issues
Common Causes:
Blunt blades
Misalignment
Low pressure
Worn components
How to Fix It:
Replace blades, check pressure, and inspect assembly.
6. Machine Will Not Start
Common Causes:
Emergency stop active
Guard open
Low air pressure
Power issues
How to Fix It:
Check safety stops, guards, air supply, and control panel alerts.
7. Date Coder Problems
Common Causes:
Incorrect ribbon
Worn printhead
Wrong temperature
How to Fix It:
Reinstall ribbon, clean printhead, and adjust timing.
8. Film Wrinkling
Common Causes:
Uneven tension
Worn rollers
Poor film quality
How to Fix It:
Adjust tension and inspect rollers.
9. Lack of Maintenance
Daily Checks:
Clean sensors
Remove residue
Inspect belts
Check air pressure
Weekly Checks:
Lubricate parts
Inspect blades
Check connections
Benefit:
Reduces breakdowns and improves efficiency, especially when using modern packaging machines.
10. Older Machinery Issues
Older machines can become unreliable and costly to maintain.
Modern machines offer:
Faster throughput
Better sealing
Lower waste
Improved efficiency
Upgrading to newer systems such as HFFS machines or VFFS machines can significantly improve reliability and output.
