MACHINE SELECTION · HUGO BECK

Hugo Beck FLEXO 500 and 700 — choosing a film wrapping machine

Repeatable high-volume production and demanding packaging applications. Explore how we configure FLEXO around the product, pack format and required production rate.

Author: Kamil Woliński

What distinguishes the FLEXO series?

FLEXO combines continuous longitudinal side sealing with intermittent transverse sealing. It serves a wide range of formats and applications. We select the product guidance, sealing system and film, together with a shrink tunnel when shrinking is required. Explore Hugo Beck FLEXO and SERVO X automatic packaging machines (PL) and their configuration options.

What helps with day-to-day FLEXO operation?

Returning to proven settings

Recipe memory helps restore parameters when returning to a previously packed product. Changing formats between batches still requires the machine to be set up correctly.

Controlled film trim handling

A controlled soft start of the trim rewinder reduces sudden pulls on the film. This is one of the features that supports a stable sealing process.

Access for operation and maintenance

Component accessibility and straightforward operation matter during material changes, cleaning and planned maintenance. Assess them alongside machine throughput.

FLEXO 500 or 700?

Selection factor	FLEXO 500	FLEXO 700
Starting point	Repeatable high-volume production, with settings matched to the product and batch	Larger formats, including product widths up to 680 mm in a suitable configuration
Rated throughput	Up to 6,000 cycles/hour	Up to 5,000 cycles/hour
Final selection	Product dimensions and shape, film type, infeed method and the throughput required from the complete line

The maximum machine cycle rate does not automatically equal the output of a complete installation. Product length, spacing, conveying, sealing time and the shrink process all affect throughput.

Long products: the flexibility of side sealing

Side sealing does not confine the product within a sealing frame of one fixed length. This allows configurations for mouldings, profiles and other long products, including items several metres long. Product length is considered when specifying conveying, support, controls and any shrink tunnel. For these applications, conveyor speed in metres per minute can be as relevant as packs per minute.

Product position and printed films

In the systems described here, the position of a detected product is tracked by the distance travelled along the conveyor. Detection before the product enters the centre-folded film allows opaque films to be used. An optional print registration sensor additionally synchronises film movement and sealing with the printed design. These functions are specified for the particular machine configuration.

Applications that demonstrate configuration flexibility

Mouldings and profiles

Long products require stable guidance and suitable discharge arrangements. Available options include forming flat film into centre-folded film and adding an easy-opening tear strip.

Furniture handles

Irregular shapes require suitable detection and transfer between conveyors. The application shown uses a light curtain and conveyors that move closer together.

Electrical components

Small items need stable transfer, with the film and seal matched to the required pack presentation.

Paper reams and bundles

Stack alignment and the right shrink process help maintain neat corners and overall pack presentation.

E-commerce shipments

Dedicated versions automatically adapt the pack to the order. Explore FLEXO 700 e-com and paper packaging machines for shipping.

Trays and product sets

Product support, packaging material and shrinking are selected according to tray rigidity and contents.

FLEXO or SERVO X? Differences you can see in the finished pack

FLEXO is the entry-level series of Hugo Beck automatic film wrapping machines, including shrink wrapping applications. It combines continuous side sealing with intermittent transverse sealing, consistent operation and good throughput. SERVO X is a more advanced platform for demanding requirements in pack presentation, material consumption and production speed.

Product stability and sealing sequence

In the FLEXO arrangement compared here, transverse sealing takes place before longitudinal sealing. SERVO X reverses that sequence: side sealing precedes transverse sealing, while vacuum conveyor belts help stabilise the product during transport. The difference therefore involves the entire product and film handling process, rather than simply intermittent or continuous operation.

Bag geometry and finished pack appearance

When the longitudinal sealing unit pulls the film downstream of the transverse sealing position, the bag can become slightly skewed. In the SERVO X arrangement, completing the side seal before the transverse cut helps produce a regular rectangular or square bag. This supports an even fit around the product and a neatly finished pack after shrinking.

Smaller film allowances

Precise product and film handling and SERVO X sealing systems allow a closer fit, reducing excess film allowances and waste. POLPACK experience shows that, in suitably selected applications, film consumption can be approximately 15–20% lower than on FLEXO. The result is verified through trials with the specific product, film and settings; it is not a fixed saving for every pack.

Higher throughput

Rated output is up to 6,000 cycles/hour for FLEXO 500 and up to 5,000 cycles/hour for FLEXO 700. The standard SERVO X series covers five performance classes, reaching up to 15,000 cycles/hour. These are maximum figures for different configurations, not the output of every machine; actual performance depends on the product and line configuration.

When should you choose FLEXO? When you need a robust, versatile machine for repeatable high-volume production. Product or size changes between batches require the appropriate changeover and settings; this does not mean alternating randomly sized products. When should you choose SERVO X? When precise bag geometry, close film fit, reduced film consumption and high throughput are particularly important.

What is ionisation sealing in packaging machines?

Ionisation sealing is the industry term used for a neat longitudinal film closure using ionisation. On a suitably equipped SERVO X-class machine, it can produce a near-invisible join, keeping attention on the product and its presentation.

It is particularly worth considering for cosmetics, boxed chocolates, pralines and other premium products that benefit from a clean, elegant finish. The closure method and film are selected together: the result depends on the material, product format and process settings. Ionisation is an option for a particular configuration, rather than standard equipment on every SERVO X machine.

POLPACK DCL-B film performs well in these applications. Explore POF films for packaging and ionisation sealing and arrange a trial with your product.

The machine and film form one process

We match film formulation and gauge to the sealing system, required presentation and product protection. A trial establishes whether a thinner material is suitable and how much film will be consumed. The film must maintain the required pack performance; reducing gauge alone is not the objective.

Selecting film for FLEXO

Explore POF shrink films for automatic packaging machines, including thin-gauge Performance films. We confirm the formulation and gauge using your product and the intended sealing and tunnel settings. If you are considering paper instead of film, discover OLYMPIA PAPER heat-sealable paper (PL); suitability requires assessment of the specific machine configuration and trials.

Trials, installation and servicing

We have worked with Hugo Beck on machine selection and installation for nearly 25 years. Tell us about your product, formats, material and required throughput. We will agree the trials, configuration, installation requirements and training. After commissioning, we provide local technical support and material selection.

Frequently asked questions

Can FLEXO work with an existing line?

We assess this based on the product infeed, required throughput, available space and control system.

Does every application need a shrink tunnel?

No. A tunnel is needed when the selected film and required pack finish involve shrinking.

What information is needed to select a machine?

Product dimensions and samples, planned formats, required throughput, film type and information about the installation area.