As global markets shift toward lightweight, portable, cost-efficient packaging, liquid sachets have rapidly become one of the most popular formats for food, beverages, cosmetics, daily-care liquids, condiments, supplements, and travel-size products.

More brands—especially startups, DTC sellers, online stores, and OEM factories—are adopting VFFS machines (Vertical Form Fill Seal Machines) for their liquid sachet production.
Among them, the ZONESUN ZS-FS200D Liquid Sachet Filling & Sealing Machine stands out for its efficiency, compact design, and affordability.

This article provides a complete optimized overview:
✔ What is a VFFS machine
✔ Why liquid sachets are trending
✔ Benefits and challenges of VFFS technology
✔ A real-world case study
✔ Why ZONESUN offers a high-ROI solution

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What Is a VFFS Machine? (Vertical Form Fill Seal Machine Explained)

A VFFS machine is an automated packaging system that forms bags from roll film, fills them with product, and seals them vertically.

How a VFFS Machine Works

• Roll film is pulled into the forming tube
• Film is shaped into a pouch (3-side seal, 4-side seal, pillow bag, sachet, or stick pack)
• The liquid filling system injects a precise volume
• The hot sealing jaw seals the top and bottom
• The pouch is cut into individual sachets

A VFFS machine can package:

• Liquids (juices, sauces, oils, serums, disinfectant, shampoo)
• Semi-liquids (gel, honey, creams)
• Powders & granules with the right filler

This combination of speed, automation, and flexibility makes VFFS one of the most widely used liquid packaging technologies globally.

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Why VFFS Machines Are Ideal for Liquid Sachet Packaging

⭐ 1. High production efficiency

A single vertical form fill seal machine can replace several manual workers.
This results in higher output, consistent quality, and reduced errors.

⭐ 2. Lower packaging cost using roll film

Roll-stock film is significantly cheaper than pre-made bags—often 20–40% less—helping reduce long-term operating costs.

⭐ 3. Flexible pouch styles

A VFFS machine can make:

• 3-side seal sachets
• 4-side seal sachets
• Pillow bags
• Stick packs
• Multi-lane small sachets (with upgraded systems)

⭐ 4. Perfect for small businesses & startups

Compact size + low investment → fast ROI.
It is ideal for new brands testing products, private label sellers, or contract packers.

⭐ 5. Consistent sealing quality

Automatic temperature control ensures proper liquid sealing without leakage—critical for food, cosmetic, and pharmaceutical use.

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Global Market Trends: Why Liquid Sachets Are Growing

✔ 1. Rising demand for single-use and travel-size products

Convenience buyers prefer lightweight, easy-tear sachets for:

• Shampoo
• Sauce & condiments
• Functional beverages
• Skincare samples
• Energy gels

✔ 2. Perfect format for e-commerce & cross-border shipping

Sachets reduce freight costs and survive shipping better than bottles.

✔ 3. Popular for promotional samples

Brands use sachets to introduce new product lines or flavors.

✔ 4. Low-risk solution for new brands

Small sachets allow businesses to test the market with minimal cost.

Liquid sachet packaging is no longer a trend—it is a long-term consumption pattern.

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Challenges of VFFS Liquid Packaging (And How to Solve Them)

1. Initial investment cost

Solution: Choose an affordable model like ZS-FS200D designed specifically for SMEs.

2. Requires proper sealing temperature & parameter setup

Solution: ZONESUN provides remote guidance + startup training.

3. Liquid viscosity affects filling performance

Solution: Customize pumps (gravity pump, gear pump, piston pump) based on the product.

4. Film quality matters

Solution: Use reliable laminated films such as PET/PE or PET/AL/PE for leak prevention.

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Case Study: Using ZS-FS200D to Launch a Liquid Energy Shot Brand

Brand: Boost+ Functional Drinks

A startup wanted to launch 50 ml single-serve energy shots for online retail.

Challenges

• Limited budget
• Need professional, attractive sachets
• Required 40–60 ml flexible filling range
• Needed fast production with minimal staff

Solution: ZONESUN ZS-FS200D VFFS Liquid Sachet Machine

• Produces 3-side & 4-side sealed sachets
• Compact footprint, easy to operate
• Consistent sealing, no leakage
• Cost-efficient consumables (roll film)

Results

• Packaging cost reduced by 30%
• Output increased 5× compared to semi-manual filling
• SKU switching became simple (flavors, sizes)
• Successfully entered convenience stores and TikTok Shop markets within 90 days

This demonstrates how a single VFFS machine can transform a small brand into a scalable business.

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Why Choose the ZONESUN ZS-FS200D?

✔ Affordable & ideal for small businesses

✔ Supports a wide range of liquids

✔ Consistent sealing quality and accurate filling

✔ Works with inexpensive roll-film

✔ Small footprint—perfect for limited factory space

✔ Easy operation & low maintenance

It's one of the best entry-level vertical form fill seal machines for liquid sachet production.

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About ZONESUN

ZONESUN is a global manufacturer specializing in packaging automation equipment, including:

• VFFS liquid sachet packing machines
• Liquid filling machines
• Labeling machines
• Capping machines
• Vacuum & sealing machines
• Customized packaging production lines

With customers in 100+ countries, ZONESUN is recognized for:

• High cost-performance
• Easy-to-use machines
• Strong technical support
• Flexible customization

ZONESUN helps startups, SMEs, and factories build efficient, modern packaging systems with minimal investment.