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Troubleshooting Packaging Film Issues in Flow Wrapping: Common Problems and How to Solve Them

October 2025

Packaging film is the lifeblood of any flow wrapping operation. It protects the product, communicates the brand, and ensures compliance with safety and labelling regulations. But even the best flow wrapper will underperform if the packaging film isn’t running correctly. Wrinkles, poor seals, misregistration, or tearing can cause downtime, product waste, and frustrated operators.

In fact, studies show that packaging material waste can account for 10–15% of total packaging costs if not properly managed (PMMI Business Intelligence, 2023). That number climbs even higher when film issues cause rework, product loss, or missed shipments.

In the table below, we’ll walk through the most common film issues seen on flow wrappers, their root causes, and how Omori’s engineering and service teams help clients overcome them. Scroll horizontally for full details.

Flow Wrapping Issues: Symptoms: Causes: Solutions: Omori Advantage:
1. Poor Seal Integrity Open seams, leaking packages, or seals that peel apart easily.
  • Incorrect sealing temperature or dwell time.
  • Contamination (oil, crumbs, moisture) on the seal area.
  • Film not designed for the sealing method being used (e.g., cold-seal film on a heat-seal jaw).
  • Uneven pressure from worn or misaligned sealing jaws.
  • Verify sealing jaws are at the correct temperature and pressure.
  • Inspect film compatibility: multilayer barrier films may require higher dwell times, while sustainable mono-material films often need tighter tolerances.
  • Implement regular jaw cleaning and preventive maintenance.
 We engineer custom sealing systems (heat, cold, rotary, ultrasonic) and run film validation tests to ensure reliable seals.
2. Film Tracking & Misalignment Film drifts sideways during operation, creating skewed packages or crooked seals.
  • Uneven film roll tension or incorrect threading.
  • Worn rollers, belts, or misaligned formers.
  • Variations in film thickness or stretch.
  • Calibrate tension controls and check alignment of rollers and formers.
  • Inspect film rolls for consistent quality; fluctuations in gauge or width can create chronic tracking issues.
  • Add edge-guiding systems or sensors for precise film control.
 Advanced servo-driven film handling systems reduce misalignment, even at high speeds.
3. Film Tracking & Misalignment Visible wrinkles in the film, affecting product appearance and shelf appeal.
  • Incorrect forming box size or angle.
  • Film tension too high or too low.
  • Film not matched to product geometry (e.g., stiff laminate over irregular product).
  • Re-engineer forming boxes to match product dimensions more closely.
  • Adjust film feed and tension parameters.
  • Choose films with the right flexibility or stretch characteristics.
 Custom forming boxes and product handling systems are designed in-house to minimize wrinkling and maintain premium presentation.
4. Registration Errors (Print Misalignment) Logos, barcodes, or graphics appear off-center or cut off.
  • Registration sensors not calibrated.
  • Slippage between film feed and product feed.
  • Inconsistent print repeat length from supplier.
  • Regularly calibrate and clean registration sensors.
  • Ensure synchronization between infeed conveyor and film drive.
  • Work with film suppliers on print repeat tolerances.
 High-precision servo controls and intelligent film feed software maintain registration at high speeds.
5. Film Tearing or Breaking Film snaps mid-run, causing stoppages.
  • Excessive tension or sharp edges on machine parts.
  • Poor film quality or micro-defects in roll.
  • Temperature settings too high, weakening film.
  • Check for worn or sharp machine components that cut film.
  • Lower sealing temperatures if film is melting or thinning.
  • Conduct incoming film inspections to catch weak spots before running.
 Our service team trains operators in proactive inspections and adjusts machines to handle even thinner, sustainable films without tearing.
6. Static Electricity

Film clings to rollers, products, or operators, causing jams.

 
  • Dry environments generate static buildup.
  • Non-conductive film materials (especially clear mono-materials).
  • Install ionization bars or anti-static devices.
  • Maintain humidity at recommended levels in packaging rooms.
  • Use anti-static film coatings where available.
 We integrate anti-static controls into wrapper design for sensitive products and environments.

Preventive Measures: Building a Reliable Packaging Film Strategy

When it comes to flow wrapping and film, reactive troubleshooting is costly. A preventive approach to reduce downtime and improve efficiency. Consider:

  • Regular Maintenance & Calibration: Scheduled jaw cleaning, roller checks, and software updates.
  • Film Validation Testing: Run new film types (e.g., recyclable PE) on the machine before full production.
  • Operator Training: Skilled operators recognize early signs of film issues, reducing escalation.
  • Vendor Partnerships: Omori works closely with film suppliers to ensure material compatibility and availability.

Film issues are inevitable in flow wrapping, but downtime and waste don’t have to be. By understanding common problems and applying proven solutions, manufacturers can safeguard efficiency and product quality. With Omori’s expertise in machine customization, film validation, and operator training, even the toughest film challenges can be resolved before they impact your bottom line.

Interested in a partner with the expertise to solve your flow wrapping film challenges? Let’s talk! Fill out the form below.

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