Tissue Wrapping Machine :

Flow Wrap vs. Pillow Pack Machines

1. Introduction

In the tissue industry, packaging plays a crucial role not only in protecting products from moisture, dust, and damage, but also in boosting shelf appeal and operational efficiency. Whether you’re wrapping facial tissues, toilet rolls, or folded napkins, selecting the right packaging method can significantly impact speed, cost, and product presentation.

Two of the most commonly used wrapping technologies today are flow wrap machines and pillow pack machines. Each offers distinct advantages depending on the type of tissue product and production requirements.

In this guide, we’ll compare flow wrap and pillow pack machines across performance, cost, design, and application—so you can make an informed decision that fits your production line and business goals.

2. What Is a Flow Wrap Machine?

A flow wrap machine is a high-speed, horizontal packaging system designed to wrap products in a continuous film. It works by feeding products through a series of rollers where a plastic or paper film is folded around them, sealed on the sides and ends, and then cut into individual packs.

These machines are ideal for mass production lines due to their speed and efficiency. The entire process is automated—from film feeding and sealing to cutting—making them suitable for consistent, high-output packaging operations.

Flow wrap machines are commonly used to package:

• Facial tissues
• Boxed tissue refills
• Wet wipes
• Pocket tissue packs

Thanks to their tight, sleek finish and fast operation, flow wrap machines are perfect for manufacturers aiming for both visual appeal and efficiency.

3. What Is a Pillow Pack Machine?

A pillow pack machine is a type of vertical or horizontal form-fill-seal packaging machine that creates pillow-shaped packs—named for their soft, rounded edges and air-cushioned appearance. These machines form a pouch from a flat roll of film, fill it with the product, and then seal the edges to create a compact, sealed unit.

The working mechanism involves:

• Forming the film into a tube shape
• Inserting or dropping the tissue product into the tube
• Sealing both ends and the back to form a secure package

Pillow pack machines are widely used for products that don’t require a rigid outer casing but still need compact, protective packaging.

Common products include:

• Toilet paper rolls
• Handkerchief packs
• Small folded tissue bundles
• Mini travel-size tissues

They’re particularly popular for bulk packaging, cost-effective shipping, and space-efficient storage, especially in high-volume retail and institutional supply chains.

4. Key Differences Between Flow Wrap and Pillow Pack

Feature	Flow Wrap Machine	Pillow Pack Machine
Packaging Style	Flat, tight horizontal wrap around the product	Air-cushioned, pillow-shaped packs
Operation Direction	Horizontal form-fill-seal	Typically vertical form-fill-seal (can be horizontal too)
Best for	Facial tissues, wet wipes, boxed tissues	Toilet rolls, handkerchiefs, compact folded tissues
Speed & Efficiency	High-speed, continuous motion ideal for fast output	Moderate speed, suitable for products with flexible shape
Film Usage	More precise wrapping with less film wastage	Slightly more film used due to air-filled shape
Product Protection	Tighter wrap, good for structured items	Better cushioning, ideal for softer or fragile products
Shelf Appeal	Sleek, neat appearance with visible branding area	Distinct shape, often perceived as more premium
Footprint & Layout	Requires more horizontal space on production lines	Requires more vertical space in layout

In summary, flow wrap machines excel in speed and minimal packaging, making them perfect for flat or boxed items. Pillow pack machines, on the other hand, offer cushioning and flexibility, making them ideal for softer or round tissue products. The right choice depends on your product shape, speed needs, and packaging goals.

5. Pros and Cons

Understanding the advantages and limitations of each packaging method can help tissue manufacturers choose the best fit for their production needs.

Flow Wrap Pros:

• High Efficiency: Designed for continuous, high-speed production—great for large volumes.
• Compact Appearance: Produces tight, uniform packages that are easy to stack and display.
• Ideal for Flat or Stacked Products: Works best with facial tissues, wet wipes, and napkin stacks.

Flow Wrap Cons:

• Limited Shape Compatibility: Not well-suited for round or irregularly shaped products like toilet rolls.
• Precision Required: Accurate product alignment is essential to avoid miswraps or jams.

Pillow Pack Pros:

• Versatile for Shapes: Ideal for wrapping soft, round, or irregularly shaped products such as toilet rolls or folded tissues.
• Simpler Film Sealing: The vertical form-fill-seal method makes sealing straightforward and adaptable.

Pillow Pack Cons:

• Bulkier Package Size: Air cushioning creates a larger footprint per pack, which may affect storage and shipping efficiency.
• Potential for Higher Material Usage: Slightly more film may be needed to accommodate the puffed-up shape.

Each machine has its place—flow wrap suits fast-moving, flat-packed lines, while pillow packs shine in bulkier, consumer-friendly applications. Next, let’s explore which factors to consider when choosing the best fit for your operation.

6. Cost Considerations

When investing in a tissue wrapping solution, it’s essential to evaluate both the initial investment and long-term operational costs to ensure profitability and production efficiency.

Initial Machine Cost Comparison

• Flow Wrap Machines: Typically more expensive upfront, especially high-speed models with automation features. However, they offer faster ROI for high-volume production environments.
• Pillow Pack Machines: Generally more affordable in terms of machine price. Ideal for small to medium-sized businesses or startups with limited capital.

Operational Costs

• Film Usage:
  • Flow wrap machines are more efficient in film consumption due to tighter packaging.
  • Pillow pack machines may require more wrapping material due to the looser pillow shape.
• Energy Consumption:
  • Flow wrap machines may consume more power due to high-speed motors and precision sensors.
  • Pillow pack machines are usually simpler and may require less energy.
• Maintenance:
  • Flow wrap systems have more moving parts, requiring regular calibration and maintenance.
  • Pillow pack machines have fewer precision components, typically resulting in lower maintenance costs.

Downtime and Production Loss

• Flow wrap machines, while faster, are more sensitive to misalignment or film issues, leading to potential stoppages if not well-maintained.
• Pillow pack machines are more forgiving but may be slower, affecting total output.

Bottom Line: Flow wrap is more cost-effective for high-output, precision-oriented operations, while pillow pack suits flexibility and budget-conscious production lines. The right choice depends on your product type, output needs, and investment capacity.

7. Which One Suits Your Tissue Product Line?

Choosing between a flow wrap or pillow pack machine depends heavily on the type, shape, and packaging goals of your tissue product line:

Flow Wrap Machines Are Ideal For:

• Flat or stacked items like:
  • Facial tissues
  • Interfolded napkins
  • Wet wipes (stacked format)
• Brands prioritising:
  • Tight, compact packaging
  • High-speed automation
  • Retail-ready shelf presentation
• Environments where speed and visual appeal are key.

Pillow Pack Machines Are Best Suited For:

• Bulky or round-shaped products like:
  • Toilet rolls
  • Handkerchief packs
  • Soft-folded kitchen towels
• Operations needing:
  • Simpler setup
  • More tolerance for irregular shapes
  • Lower-cost entry into automation

Hybrid or Dual-Pack Solutions:

• If you produce multiple product formats (e.g., toilet rolls + facial tissues), consider:
  • Dual-line setups (separate machines for each)
  • Modular or adjustable wrapping systems that switch modes
• This adds flexibility and maximises ROI across your tissue product portfolio.

Conclusion: Match your machine to your product form and market demand—flow wrap for precision and speed, pillow pack for bulk and versatility.

Looking to upgrade your tissue packaging line?

At Dechangyu, we specialise in advanced tissue converting and packaging machinery to suit your specific product and production goals. Whether you’re producing facial tissues, toilet rolls, or multi-format lines, our expert team can help you find the optimal solution.

Get in touch today for a free consultation. Let’s streamline your packaging for better speed, efficiency, and presentation.