Solutions for Manufacturing Flex Film Bags image

Solutions for Manufacturing Flex Film Bags

From plastic bags used by retailers to garbage bags utilized by virtually everyone, packaging made from flex film is ubiquitous in modern society. Originally introduced to the marketplace as an environmentally friendly, convenient, and cost effective alternative to paper bags, these products are now just as likely to be seen caught in fences along roadsides and floating in waterways as they are in stores and pantries. As a result, manufacturers now use biodegradable variants of flex film for most consumer applications. These composites require special recipes and divergent blends, and wider temperature ranges. In addition to the use of new materials, flex film bags continue to evolve into countless shapes, sizes, and configurations. Morrell has long been an important resource for systems and components relating to the manufacture of all forms of flex film packaging. We routinely provide solutions that allow for faster and more efficient processes featuring quick changeover capabilities, energy efficiency, and reduced heat signatures, all within a smaller footprint.

Engineering, Manufacturing, and Quality Support

As demand for bags and other flex film packaging types continues to grow, the need for full service motion and control solutions from Morrell has increased as well. Manufacturers are continuously looking to optimize every aspect of their operations. This begins with getting the most out of their existing facilities and ends with realizing higher quality products through the optimization of converting techniques performed by their machinery. Customers benefit from our experience in utilizing systems that enable flexible manufacturing, thereby accommodating the enormous range of products they are tasked to produce. The results have led to quick changeover capabilities that allow for the production of standard garbage bags on one shift and perforated bags on the next. The ultimate conclusion of our involvement with manufacturers of flex film packaging are measurable gains in energy efficiency, quieter work environments, less heat emissions, and increased uptime with higher quality final products.


Morrell’s commitment to providing efficient, reliable, and precise motion control solutions to our customers involved in the production of flex film bags begins with our dedication to comprehensively assess their needs. Our customers benefit from access to the deepest product selection available in the industry. We retrofit existing machines with controls architecture and components that function within their specified parameters. This promotes safety by enabling operation within the exact specifications established by the manufacturer. We provide a full portfolio of safety products from sensors and gates to pull cords and guards to prevent unauthorized human interaction with all moving parts. Morrell’s approach to upgrading manufacturing systems and processes is geared precisely to provide measurable increases in uptime while improving the safe and trouble free operation of our customers’ processes.


One of the most intriguing manufacturing processes to observe is the extrusion central to making flex film for plastic bags. It begins with a precise mix of high and low density resins. This material then proceeds to a heated barrel where a bubble is formed and blown upward within the extrusion tower, forming a tube of molten plastic often two or more stories tall. Morrell provides solutions for every step of this unique extrusion process. Sensors are incorporated to monitor the process so the proper blend, temperature, and thickness of the material are maintained for consistent quality. High-end pumps and valves ensure the exact flow required. For hydraulic processes we provide filtration to ensure longevity of the system. Safety sensors and gating keep plant personnel at a safe distance. All of this is connected through a centralized controls architecture that allows for simple integration within the facility’s process database as well as enabling quick changeover to accommodate different flex film materials for use with other products.

Sealing / Cutting / Perforating

Flex film used for producing plastic bags must be sealed, cut to size, and perforated to allow for the end user to tear away one bag at a time. These machines are often mobile for utilization with multiple lines and must therefore be configured for quick changeover for a multitude of bag types. All functions of these machines must occur in concert with one another at an extraordinarily rapid pace to avoid jamming or entangling. For over forty years Morrell has specialized in the synchronization of multiple axis points throughout virtually every manufacturing process. We design and execute motion and control systems that orchestrate the entire process. The controls of the machine are integrated with the entire process for seamless inclusion, controlling speed and function. Implementing sensor technologies allows for temperature, edge guiding, perforation, and seal validation to ensure consistent quality. Morrell can also provide all mechanical aspects of these machines including linear modules, ball screws, and linear bearings for years of smooth, trouble free performance.

Folding / Pleating

Once the bags are sealed, cut, and perforated the material must then be folded and pleated. Pleating the material is what allows for expanded capacity of a flex film bag and helps to prevent the product from tearing or bursting. Folding then conforms the material to the exact size required for winding and eventual packaging. Since this is essentially the finishing stage of flex film bags it is imperative that all folding and pleating not only is executed within exact specifications per unit but must be replicated for the entire amount of material being converted. Morrell is a crucial partner for providing motion and control systems and components required for folding and pleating. The exact and delicate nature of these processes requires pneumatic cylinders and valves for material handling. Mechanical aspects of this stage are accomplished through both rail and block tracks. Sensors are also incorporated to further ensure quality by measuring and checking the integrity of all pleats and folds. Morrell is also central to the long-term maintenance of this equipment, offering the ability to ship all relative replacement parts with pre-scheduled, same day or overnight delivery.


The step immediately prior to final packaging is the winding stage. It is here flex film bags are wound into rolls anyone who purchases garbage bags is familiar with. This is an extremely fast paced function and requires precise controls architecture to enable rolls of various quantities of bags per roll. Morrell works with customers ranging from builders of winding machines and flex film bag manufacturers for both new machines and upgrading existing winders. Pneumatic cylinders and valves are used to handle the material and the air is filtered, regulated and lubricated to keep the pneumatic system performing without interruption. We also provide mechanical components to accommodate flex film products ranging from very small to very large for high speed and high torque settings, respectively. We assist our customers in their efforts to reduce the footprint of winding machines as well as sensors to keep plant personnel safely out of harms way and to ensure quality. All of this is connected with accompanying machinery for precise winding in preparation for final packaging and shipping.

Morrell’s customers involved in the manufacture of flex film bags require converting solutions that optimize energy efficiency, reduce noise emission, and ultimately equate to consistent and high quality final products. The nature of the production of these products requires flexible controls architectures coupled with systems and components to enable quick changeover as well as the ability to accommodate high torque for larger flex film bags and high speed for smaller ones. We are frequently brought in early in the process for both new machine design and retrofitting existing systems. For over forty years Morrell has remained a leader in virtually every industry where automation is the foundation of operations. This is why Morrell serves as a single source solution for optimizing and maintaining machinery involved in every step of the production of flex film bags.

Engineering, Manufacturing, and Quality Support:
  • Facility Planning
  • Process Planning
  • Product Planning
  • Reverse Engineering
  • Laser & White Light Scanning
  • Ergonomic Studies
  • Virtual Prototyping
  • Component Sizing & Selection
  • Engineering Support
  • Manufacturing
  • Electrical Engineering
  • Field Wiring
  • Electrical Control & Panel Design
  • Full System Installation
Solutions for Flex Film Bag Manufacturing:
  • Extruding
  • Sealing
  • Cutting
  • Perforating
  • Folding
  • Pleating
  • Winding
Engineering, and Build Standards:
  • UL Certified
  • NFPA
  • CE
  • CUL
  • OSHA
  • 2003 ISO 9000/2000
  • 2004 TE 2000
  • 2006 ISO 9001:2000
  • 2009 ISO 9001:2008

Additional Information:

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