In industrial packaging, it may be necessary to include mandatory or variable information on the bag, such as the lot code, production data, product code, ingredients, recipe, product code, product family, or other specific information.
The point isn't just to print information. The point is to understand when that information needs to be included, where it needs to be applied, on what material, and with what level of production variability.
In many cases, this information must be included before the bag is used or shipped as a finished product. For this reason, the choice between direct printing on the film, applied labels, inkjet printing, or other technologies must be evaluated in relation to the actual process, not as an isolated decision.
When the information must be printed on the bag before the finished product is packaged
In industrial packaging, certain information must appear on the bag before the product is delivered as a finished good: lot number, production data, product code, ingredients, recipe, and product code or product family. The choice between direct printing and labels depends on the amount of data, the material, the placement, production variability, and synchronization with the machine.
For some food items or similar products, the information printed on the bag is not always the same. It may vary depending on the batch, product line, recipe, or the specific item being processed at that time.
This makes marking an integral part of the production process. It’s not enough to simply have a printer or a labeling machine: you need to determine whether the information should be printed directly onto the film, applied via a label, or handled using a different system, depending on the amount of information to be included.
In the case of vertical lines, this issue relates to film handling, bag formation, and continuous feed. Industrial packaging solutions must ensure consistency among the product, film, format, and variable information.
Direct Printing on Film: When It's the Most Integrated Solution
Direct printing on the film takes place before the bag is formed. This method is used when information needs to be printed directly onto the material, without adding a label afterward.
Print quality depends heavily on the condition of the surface. The flatter, more stable, and better stretched the film is, the better the result will be. If, on the other hand, the material is already shaped, folded, uneven, or not perfectly stable, the print will be less precise.
This aspect is particularly important because the print head does not operate independently. It must be synchronized with the film’s feed. If the film advances and the print head does not operate in coordination with it, this can lead to positioning issues, misalignment, defects, or interference with the machine’s operation.
The film is not merely the medium on which the data is printed. It is a technical variable that affects the accuracy of the result. When evaluating the range of packaging machines at VAI, film handling therefore remains a factor that must also be considered in relation to marking requirements.
Labeling: Greater Flexibility for Product Lines, Variants, and Small Batches
Labeling follows a different process. In this case, the information is not printed directly onto the film; instead, a label is applied to the bag or the film.
This solution is useful when a customer wants to keep a generic or standard roll and change only the variable information via a label. For example, a roll can have a common design, and the label can display specific information about the product family, such as “grains,” “grains,” or other reference details.
The main advantage is flexibility. If there are many product codes, numerous variations, or small production runs, it is not necessary to print a different roll each time. You can use a common base and update only the label.
Labeling, however, requires precision. Here, too, synchronization between the film, the bag, and the label feed is essential. If the label is not applied at the correct point, it may fold, peel off, get jammed in the machine, or cause defects on the package.
Inkjet, laser, and print area: Why not all technologies are suitable for every application
In addition to direct printing and labeling, there are inkjet systems that can be used to print variable data, codes, lot numbers, or technical information.
In this case, the main consideration is the amount of data to be printed and the available space. If there is only a small amount of data, a compact printer may be sufficient. If, on the other hand, a large amount of information needs to be printed, a larger print area is required.
In some cases, an area of approximately 120 x 53 mm may not be sufficient. To achieve certain heights, more print heads, more nozzles, or more complex printing systems may be required. With larger systems, it is possible to cover much larger areas, such as approximately 600 x 128 mm, but these are different, more sophisticated solutions suited to specific needs.
A concrete example involves products such as flour, buckwheat, or specialty blends. In these cases, simply printing the lot number or expiration date may not be enough: ingredients, recipes, codes, product information, and variants may also be required. For applications of this type, integration with flour-processing solutions helps contextualize the issue within a real-world production process.
Laser marking is an established technology, but it is more specialized. It can be effective when the material allows it—for example, on rigid surfaces, cans, specific components, or materials suitable for engraving and permanent marking. In the case of flexible film or bags, it should not automatically be considered the primary solution.
How to Choose: Data Volume, Material, and Production Variability
The choice between direct printing, labels, and other systems does not depend on a single factor. It depends on how the data enters the production process.
- How much do I need to print? A small amount of variable data requires a different solution than ingredients, recipes, and detailed information.
- Where should I print: on the film before forming, on the bag, or on an attached label?
- On what material: flexible film, stable surface, rigid material, or a specific substrate.
- How many SKUs do I need to manage: A dedicated reel may make sense for just a few variants, while a generic reel with variable labeling may be more suitable for many SKUs.
- How much print space is needed: Batch numbers and expiration dates have different requirements than ingredients and recipes.
- The machine requires precise synchronization: the film, print head, label, and bag must all work in coordination.
If the customer has only one product code or limited information, direct printing can be a simple and integrated solution. If, on the other hand, the customer has many product codes, many variants, or small batches, labels may be a more sensible solution. If a large amount of information needs to be printed, the print area should be evaluated before choosing a system.
That’s why there’s no one-size-fits-all solution. The right choice comes from analyzing the product, the film, the format, the data to be recorded, and the production pace. To determine which configuration best aligns with your process, it’s helpful to consult with the VAI team based on your specific situation.
