Paramount Packaging Systems: Why regular maintenance of flow wrapping machines is essential

At Paramount Packaging Systems, we’ve specialised in supplying high-speed Fuji flow machinery for over 30 years, serving industries from food and confectionery to medical devices and pharmaceuticals. Over that time one of the clearest patterns we’ve seen is how preventive maintenance (PM) separates the good operators from the great ones.

With that in mind, we’ve put this article together to highlight the myriad of benefits associated with regular maintenance of your flow wrappers.

What is flow wrapping machine maintenance?

Maintenance includes all actions to keep your machine running reliably, efficiently and safely. It typically involves:

• Scheduled inspections (daily, weekly, monthly)
• Lubrication of moving parts
• Cleaning of belts, sealing jaws, guides, sensors
• Checking and adjusting tension, alignment and temperatures
• Replacing worn components
• Verifying electrical, pneumatic/hydraulic systems are in order
• Calibration and software/firmware updates if applicable

Top benefits of regular maintenance

1. Reduced Downtime

When parts are maintained, inspected and replaced before failure, you avoid unexpected breakdowns. For high-speed flow wrappers (like those from Fuji), even a short stoppage can cost thousands in lost output and labour.

2. Improved Product Quality & Consistency

Consistent sealing, correct tension, accurate wrapping speed, good cutting, all depend on well-maintained machinery. Poor sealing or misfeeds lead to rejects, waste, customer complaint, or even safety issues, especially in food and pharmaceuticals.

3. Extended Machine Lifespan

Worn bearings, misaligned belts or gears, poor lubrication etc. all accelerate wear. Regular maintenance postpones expensive replacements and delays the need to buy new machinery.

4. Better Efficiency & Lower Running Costs

A well-maintained wrapper uses less energy, fewer spare parts and less wasted product due to miswraps or rejects. Over time, these savings can be substantial.

5. Enhanced Safety & Regulatory Compliance

Especially for food, medical and pharmaceutical sectors, there are hygiene, safety and regulatory standards to meet. Poor maintenance can lead to contamination, hygiene hazards, safety violations or recalls. Regular checks help ensure compliance and reduce risk.

6. Predictable Planning & Budgeting

Scheduled maintenance means you can plan for downtime, order spares in advance and budget maintenance costs. Contrast that with reactive maintenance: surprises, rushed fixes, inflated costs for emergency parts or overtime.

7. Uptime for Innovation

When your machines are reliable, you can focus on fine-tuning your packaging styles, optimising throughput, improving pack presentation or scaling up, rather than fighting fires.

Common issues that regular maintenance prevents

• Sealing failures (poor seals, leaks)
• Mis-wrapping or jams
• Blade or cutter dullness leading to ragged cuts or safety issues
• Overheating of motors or gearboxes due to friction
• Belt slippage or excessive tension causing breakdowns
• Sensor misalignment or fouling (leading to misfeeds or stoppage)
• Accumulation of dust/build-up causing hygiene risks or affecting performance

Best practices for maintenance

• Create and stick to a maintenance schedule daily, weekly, monthly and annual checklists
• Train operators & maintenance staff in correct procedures: cleaning, lubrication, blade changing etc.
• Maintain a spares inventory of high-wear parts so machine downtime is minimised
• Document all maintenance (what was done, when, who). This helps trace recurring problems and allocate resources
• Use OEM (Original Equipment Manufacturer) parts.
• Proactive condition monitoring: vibration analysis, thermal imaging, etc. if feasible

A necessity. Not a luxury.

Regular maintenance of flow wrapping machines is not just a maintenance department’s chore, it’s a strategic imperative. The benefits include better reliability, consistent packaging quality, cost savings, safety and compliance. For a business using high speed wrapping equipment, the cost of neglect far outweighs the time and investment in proper upkeep.

If you’d like help assessing the maintenance needs of your wrappers, planning a maintenance schedule, sourcing reliable parts or training staff, Paramount Packaging Systems is here to help. Get in touch.

This article was originally published by Paramount Packaging Systems.