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. |
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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. |
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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. |
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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. |
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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. |
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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.
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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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August 2026
Most food processors and manufacturers rely on a simple manual step for padding trays before packaging meats, proteins, fruits, vegetables, etc. While this process appears straightforward, it introduces hidden costs that often go unnoticed across the packaging operation
As production demands increase and consistency becomes more critical, many processors are discovering that manual tray preparation can quietly become a bottleneck, when a more efficient pre-padded tray solution is available.
Understanding the operational impact of this step helps processors identify opportunities to improve efficiency and packaging consistency.
Labor Demands in Manual Tray Padding
Manually inserting absorbent pads into trays requires dedicated labor. Employees must handle trays, align pads correctly, and maintain pace with upstream product flow. In high volume operations this task often requires multiple employees across different shifts making sure inventory levels are maintained.
This dependency on labor, especially for a task that does not directly add value to the product, is the biggest inefficiency and contributor to unnecessary cost.
Facilities that rely on manual tray padding may frequently experience:
- increased labor costs
- difficulty maintaining staffing levels
- slower line preparation
- inconsistent workflow
When staffing levels fluctuate, tray preparation can quickly fall behind production demands. This forces downstream packaging equipment to slow down or stop while operators catch up.
Inconsistent Pad Placement
Another challenge with manual tray padding is consistency. Pads may shift, fold, or sit slightly off-center depending on how quickly trays are assembled.
Even minor inconsistencies can impact the final package quality. Improper positioning may lead to wrinkled film, poor absorption performance, or compromised product presentation during handling and transport.
Common issues include
- uneven pad alignment
- wrinkled film during wrapping
- inconsistent product presentation
- increased package rejects
Consistency is critical in food packaging. Small inconsistencies upstream can lead to quality issues further down the line.
Production Slowdowns at the Packaging Line
Efficient Packaging lines depend on smooth upstream preparation. When trays are not ready as when product arrives, the entire operation is disrupted.
These delays often occur during peak production periods. when high-speed equipment is most sensitive to interruptions.
Operations relying on manual tray padding may encounter:
- packaging line interruptions
- reduced throughput
- increased operator intervention
- higher downtime
While individual delays may last only seconds, repeated interruptions throughout a shift can significantly impact total production output.
The Efficiency of Pre-Padded Trays
Complex packaging lines often rely heavily on operator expertise to manage different product formats. When settings change between shifts or operators interpret adjustments differently, packaging performance becomes inconsistent.
Flexible tray lidding technology reduces this dependency by standardizing the sealing process.
Automated controls and repeatable machine settings allow operators to select the appropriate configuration for each SKU while maintaining consistent performance. This approach helps eliminate the trial-and-error adjustments that often accompany frequent format changes.
Building Packaging Flexibility in the Line
Modern food processing requires packaging systems that can evolve with product portfolios. Equipment that supports only a narrow range of formats quickly becomes a limitation as product offerings expand.
Flexible tray lidding machines provide processors with the ability to introduce new SKUs without redesigning the entire packaging line. By supporting multiple tray types and sealing materials, the equipment allows production teams to adapt quickly to market demands.
Omori’s Lid Sealer by Frimaq is designed with this flexibility in mind. The system supports rapid format changes while maintaining stable sealing performance and consistent packaging quality.
Packaging Technology That Keeps Pace with your Product Line
SKU complexity is unlikely to decrease. As consumer preferences continue to evolve, processors must manage more packaging formats while maintaining operational efficiency.
Tray lidding technology that supports flexibility allows manufacturers to respond to these changes without sacrificing line performance.
Omori North America provides the Lid Sealer by Frimaq, a tray lidding solution engineered to handle diverse packaging formats while maintaining seal integrity and production speed. By combining flexibility and machine design, we help processors manage growing product portfolios with confidence.
Interested in exploring how Omori can help your operation manage SKU complexity while maintaining reliable packaging performance? Fill out the form below and our team will connect with you.