Sustainable materials: new paper films and thinner barrier layers
Discussions with visitors and suppliers confirmed that the transition from traditional multilayer packaging to recyclable films is the most pressing issue. In live tests, VAI heat-sealable paper-based materials and single-material barrier films, demonstrating that a vertical packaging machine equipped with custom-profile sealing bars can handle a wide variety of heat-seal windows without reducing cycle speed. Brands’ interest stems from ESG goals and regulatory pressures, but also from the marketing advantage associated with “greener” packaging. The next step will be optimizing the dosage to reduce micro-perforations and ensure the same shelf life as conventional laminates.
Automation 5.0: Edge Sensors and OPC-UA Connectivity forStable OEE
The second trend concerns the integration of smart electronics into the production line. At the booth, VAI engineers VAI how accelerometers and IR thermal cameras installed on vertical form-fill-seal machines collect real-time data and send it via OPC-UA to a cloud-based dashboard. Predictive analytics highlights temperature or vibration deviations hours in advance—enough time for fine-tuning or replacing a heating element before a shutdown occurs. Companies that participated in the demos recognized the positive impact on OEE: even a single percentage point increase in availability becomes a competitive advantage when supply chain margins are tight.
Single-serving formats: protein snacks and flour in pouches drive flexibility
The healthy-food sector is driving the trend toward 20–50-gram packages: perfect portions for vending machines, e-commerce, and in-store samples at large-scale retailers. Production line tests have shown that VAI vertical packaging machinesVAI switch from a “family-size” bag to a single-serve bag by adjusting the forming tube and film parameters via the HMI panel, without complex disassembly. This flexibility increases machine utilization, making low-volume or niche product launches sustainable.
Data analytics and traceability: from the production batch to the individual package
More and more buyers are requesting digital reports that link actual weight, production capacity, and reel ID to each batch. With the VAI platform, data is archived and can be exported as PDFs for quality audits or sent via API to the company’s ERP system. The trend goes beyond compliance: analyzing datasets helps uncover correlations between line parameters and defects, transforming the investment in vertical packaging machines into a driver of continuous improvement.
Predictive maintenance and rapid parts replacement: uptime as a measure of success
Last but not least is the focus on predictive maintenance. Plant managers are already evaluating the availability of spare parts and the manufacturer’s ability to provide remote support during the purchasing phase. VAI introduced the Service+ contract, which combines online monitoring, priority spare parts inventory, and augmented reality video assistance: solutions that reduce Mean Time To Repair and keep the investment profitable throughout its entire lifecycle.
