Commissioning a VFFS Machine For Sauce Packaging
Commissioning and Troubleshooting a VFFS Machine for Hot Sauce Packaging
We were engaged to support the commissioning of a Vertical Form Fill Seal (VFFS) machine at a brand-new facility dedicated to bulk sauce packaging for the catering industry. Unlike most VFFS lines, which typically handle dry products such as crisps or snacks, this system was designed for filling hot, liquid sauces — a setup that introduced unique technical and operational challenges.
Project Background
We were brought in to support the commissioning of a Vertical Form Fill Seal (VFFS) machine in a brand-new facility specialising in bulk sauce packaging for the catering industry. Unlike the typical VFFS lines we have worked on, which usually handle dry products such as crisps, snacks, or powders, this line was designed for hot, liquid sauce. Working with a product that is fluid, heated, and prone to flow issues introduced a completely different set of challenges compared to traditional dry-product packaging.
The situation was further complicated by the fact that the machine had already been installed but had sat idle for over six months. The factory itself was new, with an entirely fresh workforce. None of the operators had prior experience running this specific model, and even experienced staff from the company’s other factory could not step in, as the machine type and setup were different.
On top of that, the original project manager left halfway through, leaving unresolved technical and operational issues behind. By the time we were asked to step in, the site needed more than just commissioning support. It required hands-on engineering expertise and strong project leadership to bridge the gaps and get the system operational.
Our Role & Key Activities
Machine Commissioning
We collaborated closely with the OEM (Original Equipment Manufacturer) to bring the machine into operation. This involved carefully studying technical manuals, configuring the system step by step, and running trial batches. At the same time, we provided hands-on training to inexperienced operators, helping them understand both the mechanical aspects of the machine and the correct running procedures. Our goal was not just to start the line but to leave behind a trained team capable of sustaining it.
Fault Finding on Holding Tank
The line was fed directly from a process kitchen into a jacketed holding tank, which was supposed to maintain product at the correct temperature. However, during early trials, the jacket failed to heat properly. After investigation, we traced the issue to a damaged temperature sensor.
The sensor had been incorrectly installed in a cramped location during the original setup, likely rushed, and had been damaged since day one.
We diagnosed the fault, sourced a replacement sensor, and reinstalled it properly.
Once corrected, the holding tank functioned as designed, ensuring the sauce was consistently heated to the required temperature for filling.
This repair was critical, as without precise temperature control, product flow and pouch sealing would have been highly unreliable.
Product Flow Issues
Even with temperature restored, the machine faced difficulties in handling hot sauce pouches during the filling and discharge stages. The conveyor system, which normally runs smoothly with dry snacks, struggled to cope with the weight, consistency, and flow of filled liquid pouches.
We worked with the client and equipment suppliers to identify bottlenecks, adjust settings, and modify the line configuration to improve flow. These adjustments significantly enhanced throughput, reduced pouch handling problems, and increased overall efficiency.
Outcome & Reflections
Through our involvement, a machine that had been sitting idle for half a year was transformed into a fully operational packaging line. The improvements we delivered extended far beyond fixing isolated faults:
Operators gained confidence and training to run the system independently.
Technical issues were resolved by working across disciplines, from process equipment to control systems.
Collaboration with vendors and the OEM ensured long-term reliability of the solution.
This project reinforced an important lesson: commissioning is not just about turning a key and pressing Start. It is about diagnosing incomplete installs, bridging communication gaps, supporting operators, and delivering a final product that works day in and day out.
By the time we left site, the client had a running line, trained staff, and a clear path forward for scaling up their sauce packaging operations.