Innomation raises the bar for VFFS packaging with VAYU

As food manufacturers face rising material costs, changing consumer demands and increasing pressure to improve production efficiency, packaging machinery investments are being evaluated beyond initial capital expenditure. Greater emphasis is being placed on reducing material wastage, improving machine availability, minimising downtime and achieving consistent production output.

For Innomation Equipments, this changing industry requirement has shaped the development of its continuous-motion VAYU vertical form-fill-seal (VFFS) packaging machine. The company is positioning the platform as a high-performance alternative to entry-level domestic machinery and premium imported equipment, with a focus on operational efficiency and lower cost per pack.

Speaking during Gulfood Manufacturing 2026, taking place from 3 to 5 November at the Dubai World Trade Centre, Mr Harshavardhan Sripathi, Director – Sales Engineering & Operations at Innomation Equipments, discussed the engineering behind VAYU, its performance capabilities and the company's expanding focus on flexible packaging solutions.

Bringing pharmaceutical precision to food packaging

With 21 years of experience in process and packaging equipment, Innomation Equipments has traditionally focused on the pharmaceutical industry. The company has recently expanded into the FMCG and consumer goods segments, bringing its expertise in precision engineering, material control and operational efficiency to these markets.

According to Mr Sripathi, manufacturers are increasingly moving away from low-CAPEX machinery towards equipment that delivers greater long-term value through improved productivity and lower operating costs.

"Ten years ago, the entire model was based on low CAPEX but uncalculated or high OPEX. Today, the approach is shifting towards accepting higher CAPEX in return for even greater savings and long-term benefits," he said.

He highlighted product giveaway and packaging material wastage as two areas where manufacturers can achieve significant savings. Drawing on its pharmaceutical industry experience, Innomation recognises the financial implications of even small levels of excess product giveaway.

"Coming from a pharmaceutical background, we understand that even a 1% or 2% excess product giveaway can be a very costly affair. However, when we entered the food industry, we found that many manufacturers were still operating with 4–5% excess giveaway. This gives us a significant competitive advantage," Mr Sripathi explained.

The company is targeting packaging material wastage of less than 1%, alongside lower energy consumption and a more efficient machine layout.

VAYU addresses the gap in the VFFS market

The development of VAYU was driven by an opportunity identified within the Indian VFFS machinery market. Manufacturers traditionally had two broad choices: entry-level, low-CAPEX domestic machines or high-end imported equipment from established Japanese and European manufacturers.

Innomation identified a gap between these segments for machinery that could offer advanced engineering and reliable performance at a more accessible investment level.

"We identified a gap in the market for a machine that could offer reasonable performance guarantees and perform at a level comparable to European, German or Japanese machines, but at a price point that makes more sense for the Indian market," Mr Sripathi said.

Customer feedback also influenced the development process, particularly the need for a solution that could bridge the performance and investment gap.

"Our objective was to position a machine that was equivalent to the best in the market in terms of performance, while being priced much more reasonably. Ultimately, customers look at the cost per pack. Our model is to optimise the cost per pack rather than focus only on CAPEX," he added.

Reducing production costs through measurable performance

VAYU's cost-per-pack proposition is built around several operational factors, including changeover time, packaging material wastage, product giveaway and machine availability.

Frequent SKU changes can reduce productive operating time, while inaccurate filling and poor synchronisation between filling and packaging systems can increase product giveaway. Similarly, even small percentages of laminate wastage can significantly affect overall packaging costs.

Innomation guarantees 95% machine availability for VAYU, supported by features designed to minimise material losses during production.

One example is the machine's film-splicing performance. According to Mr Sripathi, VAYU wastes only one pouch during each splice, compared with approximately 10–15 pouches on typical Indian machines.

"Consider eight to ten splices a day. That means you are wasting around 100 pouches a day, or approximately 30,000 pouches per year. On our machine, only the pouch at which the splice takes place is wasted. Everything else remains on track," he explained.

Sealing performance is another important consideration. VAYU incorporates D-motion sealing technology capable of operating at speeds of up to 200 packs per minute (PPM). Mr Sripathi noted that many manufacturers typically limit D-motion sealers to approximately 150–160 PPM before moving to rotary sealing arrangements.

"With D-motion sealing at 200 PPM, we can achieve the same seal quality that manufacturers typically get at 120 PPM today. The leakage rate is 0.2% or less, or 0.1% or less in some cases. This reduces the number of rejected packs," he said.

The VAYU 330 model consumes approximately 2.7 kW at full speed. Its compact design, measuring 680 mm in width and occupying approximately 1.5 sq. m of floor space, also contributes to efficient factory utilisation. Comparable machines occupy around 2.5–3 sq. m, representing an estimated 40% reduction in floor-space requirements.

Sustained output over rated machine speed

Innomation believes manufacturers should evaluate packaging machinery based on sustained production performance rather than rated speed alone.

Mr Sripathi explained that a machine rated at 150 PPM but operating at 80% overall equipment effectiveness (OEE) effectively delivers 120 PPM. In comparison, a 130 PPM machine operating at 92% efficiency can achieve the same output with lesser wastages and lower cost per pack.

"You need to focus on maximising the output from a machine from a given quantity of input material, rather than simply investing in high-speed machines that operate at low efficiencies or adding more machines," he said.

To maintain consistent output, VAYU incorporates continuous-motion technology, a servo-driven unwinder and an offset pivoting-frame web guide that maintains the web centre within ±0.2 mm at full speed.

A low-friction floating dancer arrangement maintains web tension within ±5% of its set point. The machine also features closed-loop tension and high precision registration control, along with vacuum-driven puller belts and servo-driven sealing and pulling systems.

"All these technologies allow us to handle the web precisely, without allowing tension variations to creep in or the web to shift on the machine. Together, they help us achieve consistent output while maintaining packaging integrity," Mr Sripathi explained.

Faster changeovers for multiple SKUs

Designed for manufacturers managing multiple SKUs, VAYU offers a guaranteed format changeover time of 15 minutes or less.

The machine incorporates quick-change assemblies that allow the former tube to be removed and replaced within minutes. Roll removal and film threading have also been designed for easier access, while vertical and horizontal sealing systems can be adjusted using quick-release knobs, linear motor adjustments and manual settings with fixed readouts.

"The main problem with changeovers is the guesswork involved in making fine adjustments after the changeover so that the machine stabilises. We have eliminated that guesswork from the process. You simply set it to the required position, start the machine and it runs," Mr Sripathi said.

Reliability, flexibility and sustainability drive automation

Looking at the broader evolution of packaging automation, Mr Sripathi believes manufacturers are increasingly prioritising three factors: reliability, flexibility and sustainability.

Reliability enables predictable production and better planning, while flexibility allows manufacturers to respond to changing market demands, different pack formats and varying SKU requirements. Sustainability is closely linked to lower material wastage, reduced energy consumption and efficient use of factory space.

"People are no longer talking only about speed. Reliability, flexibility and sustainability are equally important. These are the key words across every industry that uses packaging machines today," he said.

Customer feedback also played an important role in VAYU's development, with existing customers involved throughout the design process.

"In a way, the machine has been designed by our customers, not by us. We gathered months of customer feedback during the design process, and every design and prototype was either approved or vetoed by our customers," he added.

Positive response at Gulfood Manufacturing and future expansion

Reflecting on the company's participation at Gulfood Manufacturing, Mr Sripathi described the response as very encouraging, particularly in terms of customer engagement and business enquiries.

He reported meeting approximately 180–200 visitors for detailed discussions and quotations, with interest coming from the Middle East, India and Southeast Asia.

Innomation plans to strengthen its flexible packaging portfolio. The company currently offers vertical single track and vertical multi-track technologies and is developing the upstream and downstream machinery required to supply complete packaging lines.

The company's longer-term objective is to become a single-source partner for flexible packaging requirements, particularly for manufacturers who prioritise cost per pack and total life-cycle value over initial capital expenditure.

With VAYU, Innomation aims to address this shift through a combination of engineering precision, reduced material wastage, faster changeovers and energy-efficient operation.

Innomation Equipments team is available at Stall No S-K53, India Pavillion – Sheikh Saeed Hall at Dubai World Trade Center from 3 to 5 November 2026.