Horizontal flow wrapping (HFFS) in 2026 costs $25,000-$80,000 for a servo-driven machine and is the workhorse for trayed, boxed, and bar-shaped products — biscuits, chocolate bars, bakery trays, frozen burgers, soap bars — that cannot be vertically dropped into a VFFS bag. The Lintyco LTC520 and LTC620 line configurations serve as reference points for mid-to-high speed production (40-200 bpm).
CapEx depends heavily on: (1) infeed type (belt infeed for fragile product, lug infeed for rigid product), (2) cut type (rotary knife for speed, guillotine for thick product), (3) film width capacity (80-400mm typical), (4) servo vs mechanical drive. Annual maintenance runs 8-12% of CapEx — sealing jaw refurbishment, film knife sharpening, and infeed conveyor belt replacement dominate.
Cost Breakdown
CapEx → running cost
| Cost Component | Typical Range |
| Capital expenditure (CapEx) | $25,000 - $80,000 |
| Annual maintenance | $2,500 - $8,000 |
| Energy consumption | 3.0 - 7.5 kWh/hour |
| Labor per shift | 1 operator |
Benchmarks at a Glance
2026 data
Price Range
$25,000 - $80,000
Industry Note
Flow wrapper ROI runs 12-14 months for branded snacks, bakery, and confectionery (high per-unit margin); 14-18 months for commodity frozen and household products.
Buying Decision Factors
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Infeed type: Belt infeed ($3-5k) for fragile products (biscuits, bakery). Lug infeed ($5-8k) for rigid products (boxes, bars). Servo infeed ($8-15k) for irregular shapes. Wrong infeed causes product damage or jams.
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Cut type: Rotary knife (standard, $1-2k replacement) for products under 50mm thick at 100+ bpm. Guillotine knife ($3-5k) for thick products (trays, multi-packs) at lower speed. Rotary is faster but limited to thin products.
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Film width capacity: 80-200mm width ($25-45k) for bars and small items. 200-300mm ($45-65k) for trays and bakery. 300-400mm ($60-80k) for multi-packs and large boxes. Width determines product size range.
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Servo vs mechanical drive: Servo drives ($8-15k premium) enable 150-200 bpm with quick changeover. Mechanical drives cap at 80-120 bpm. Servo pays back above 100 bpm or for frequent format changes.
Products That Use a Flow Wrapper (HFFS)
Cross-linked selectors
Frequently Asked Questions
HFFS (flow wrapping) vs VFFS — when to choose which?
HFFS for products that cannot be dropped vertically (trays, boxes, bars, bakery, fragile items). VFFS for granular and free-flowing products (snacks, rice, powder) that can drop into a vertical tube. Many lines use both for different SKUs.
Belt or lug infeed for my product?
Belt infeed for fragile and irregular products (biscuits, bakery, chocolate) — supports gently. Lug infeed for rigid and uniform products (boxes, bars, soap) — positive control. Servo infeed for mixed formats. Belt is most common.
Rotary knife or guillotine cutter?
Rotary knife for products under 50mm thick at 100+ bpm (chocolate bars, single biscuits). Guillotine for thick products (trays, multi-packs) at lower speed. Wrong choice causes product crushing or cut errors.
What film types work for flow wrapping?
OPP/CPP (oriented polypropylene) for snacks and bakery. PET/PE for trays and frozen. Foil laminate for chocolate and moisture-sensitive. Cold-seal film for chocolate and heat-sensitive products. Film cost: $0.005-0.03 per wrap.
How tight should the film wrap be?
For retail appearance, tight wrap with no wrinkles. For bakery and fragile products, slight looseness prevents crushing. Adjust film tension via brake and dancer roller. Too tight cracks product; too loose looks unprofessional.
Why are my flow wrap seals failing?
Causes: (1) seal jaw temperature drift (130-170°C for OPP/PET), (2) contaminated film at seal area, (3) inconsistent jaw pressure, (4) film thickness variation. Target <1% seal failure; above 3% indicates a problem.
Can a flow wrapper handle MAP or gas flush?
Yes — MAP/gas flush adds $10-20k and extends shelf life of bakery (14-30 days), cheese (60-90 days), and fresh pasta (21-45 days). Essential for modified atmosphere retail packaging.