Creating a tailor-made format for a packaging machine is never a mere theoretical exercise: it is a process in which every millimeter counts, because it affects stability, visual appeal, and logistical efficiency. At VAI , we have transformed this activity into a precise and proven flow that starts with a very simple analysis-the customer's sample-and arrives at an extremely complex result: a format optimized for palletization, visual appeal, and production performance.
From sample to product understanding: the first step to the ideal format
The journey begins when the customer provides us with a representative sample of the bag or format they are using. This sample is not just an aesthetic reference, but a starting point for understanding volumes, proportions and usage patterns. This is where our experience comes in: we evaluate density, product type, storage and transportation needs.
The client is not always aware of the critical issues related to his current format: he often works with a production paradigm that considers "normal" what can actually be improved. It is at this stage that, together, we identify optimization opportunities.
Density analysis and volume simulation for perfect palletizing
Once the data have been collected, our focus is on the relationship between product size and density. A product with twice the density of another, while occupying the same volume, will behave differently during packing and transport.
Using our experience and historical data, we can predict what the effect of a given size will be on the stability of the pallet. The goal is simple but crucial: palletize efficiently, avoiding overly oblong or stubby formats that compromise aesthetics and functionality.
From pre-sampling to 3D simulation: a bridge between reality and prediction
Before we get to the machine, there is a key step: pre-sampling. Here we ask the customer for a sufficient amount of product for testing and verification. We measure the real density, comparing it with the declared density, to avoid surprises during production.
At this point we enter the most fascinating part: 3D simulation. Using dedicated software, we virtually recreate the bag, evaluating proportions, stability and visual impact. This allows us to anticipate the behavior of the format in the real world, already optimizing every possible parameter at the design stage.
Pre-testing: where theory meets machine
No prediction is as good as a real test. That is why we always give customers the option of pre-testing directly in VAI. At this stage we physically make the simulated format, using the vertical packaging machine intended for the order.
Here the customer can see and touch the result: the aesthetic performance, the stability, the ease of stacking. This is the moment when all variables-from the behavior of the plastic film to the accuracy of the seals-find confirmation. Once the format is validated, we can proceed to manufacture the necessary mechanical components.
A customized format is not just a matter of "beautiful packaging": it is the synthesis of production needs, visual marketing and logistics. Starting from the sample and arriving at the 3D simulation means giving the customer not only an efficient packaging machine, but a tool capable of enhancing the value of his product at every stage of the supply chain.
If you would like to find out how we can develop your custom format, send us a request through the contact page and let's talk about it together.
