How Rollon® Durbal Rod Ends Solved Durability Issues in GIC’s High-force VFFS packaging Systems

In the fast-moving world of packaging machinery, reliability and performance are critical. GIC, a UK-based manufacturer of vertical form fill and seal (VFFS) machines, faced a persistent challenge: finding rod ends capable of withstanding the extreme static loads and dynamic stresses of high-speed sealing operations. After experiencing longevity issues with conventional components, GIC turned to Rollon Group and its Durbal Classic Line of heavy-duty stainless steel rod ends. 

The packaging industry has undergone significant transformation over the past few decades. What was once a purely functional component of product delivery has become a key differentiator in sustainability, branding, and regulatory compliance. The demand for more eco-friendly materials, such as recyclable or compostable films, has placed new and complex demands on packaging equipment. Machines are now expected to deliver higher speeds, greater precision, and increased flexibility, often while processing thinner, less forgiving materials.

These evolving requirements have led to critical innovations in machinery design, especially in high-speed systems like vertical form fill and seal (VFFS) machines. One company at the forefront of this evolution is GIC, a British manufacturer with over 40 years of experience delivering customized VFFS solutions to the food, confectionery, pharmaceutical, cosmetic, and hardware sectors.

“All our machines are designed in-house,” explains Andy Beal, Managing Director at GIC. “We develop the mechanical structure, the 3D models, the electrical design, and even the software for our servo drives. Our strength lies in full control of the process: we work with top-tier suppliers and deliver complete, customized solutions to our customers”.

Challenges of the application

At a glance, a vertical packaging machine may seem straightforward: a roll of film unwinds, forms a vertical tube, fills with product, and is sealed to create the finished bag. But this seemingly simple process involves complex mechanics and enormous forces.

“Our machines typically produce around 70 bags per minute,” explains Andy Beal. “The sealing phase is where most of the stress accumulates. When the machine enters what we call ‘lockout,’ all the motion translates into axial force – and if you’re working with thick or multilayer film or sealing liquids that require a hermetic or gas-tight seal, the forces involved are massive.”

These high forces – especially when concentrated during the sealing stroke – can easily surpass the design limits of conventional rod ends. The result was a consistent pattern of component failure and machine downtime.

“All the rod ends we had tried up until that point eventually broke down,” says Robert Webster, Operations and Technical Manager at GIC. “Our machines need to deliver a long, reliable service life for our customers, and these failures were putting that at risk.”

Additionally, the rod ends had to be resistant to washdowns, compatible with hygienic environments, and easily accessible for inspection or maintenance.

The solution

Searching for a robust solution, GIC engineers began combing through technical documentation and product catalogues. That’s when they came across Durbal, a well-regarded brand known for its precision-engineered rod ends and part of the Rollon Group.

“Durbal was already recognized in the market for high-performance rod ends and rotational components,” recalls Andy Beal. “So, we reached out to Rollon to see whether they could help us find a solution tailored to our specific mechanical needs.”

The requirement was not just about handling repetitive cycles.

“What we’re doing isn’t just dynamic motion,” continues Robert. “We’re dealing with high compression and impact loads on top of cycling. Most rod ends can handle repetitive motion well enough but what we needed was something that could take that plus the static force without compromise.”

Rollon proposed using its Classic Line heavy-duty stainless-steel rod ends built specifically for high-stress and high-speed applications. These rod ends combine low maintenance with high static load capacity, offering a perfect match for GIC’s performance criteria.

The Rollon® Durbal maintenance free rod ends installed on one of GIC’s VFFS machines. © Rollon

“The difference was immediate,” says Andy Beal. “Over the years, we’ve tested various products, but the Durbal Classic rod ends were the only ones that delivered the combination of durability, hygienic design, and performance we were after. They’ve been running reliably for over five years now and given the consistency of the product and longevity of the Durbal name, we know we can rely on them for years to come.”

What began as a trial quickly became a standard: today, GIC not only fits these rod ends into all newly manufactured machines but is also retrofitting existing systems in the field to take advantage of the proven reliability.

Going beyond the component

For GIC, machine building is a question of engineering insight: each packaging line must be adapted to the type of product, film, speed, and sealing strategy. The rod end may be a small component, but its function within the sealing system is vital.

“Our biggest challenge is always the application,” explains Robert Webster. “It’s about knowing how to move the product, form the bag, seal it cleanly, and do it fast. You need the right sealing system, discharge unit, forming collar, film feed. Everything must work together.”

Today’s materials make that challenge even more complex. As GIC notes, the industry-wide push to reduce plastic has resulted in ultra-thin films – sometimes as thin as 25 microns – that require precise temperature management during sealing to avoid sticking or tearing.

“We’re now using high-performance sealing jaw materials and various low friction coatings to meet our customers’ requirements,” adds Andy Beal. “Paper packaging is even trickier. It doesn’t like to bend, it tears easily, and it forces you to rethink the geometry of the machine. Consumers and retailers are pushing for these changes, so we have to respond.”

That’s why GIC values a supplier like Rollon: not only for the quality of its products, but for the depth of technical support.

“What’s really important to us is that Rollon doesn’t just send us catalogue items,” continues Beal. “Their engineers visit our site, analyse the application with us, and work out solutions together. It’s the same model we apply with our own customers: provide expertise, not just equipment.”

A reliable solution in a demanding industry

GIC’s packaging machines operate under extreme mechanical conditions, where the success of the system depends on the performance of every component. The repeated failure of standard rod ends posed a major reliability risk, until the introduction of Rollon® Durbal Classic rod ends, which have since delivered uninterrupted service and load handling.

By integrating these robust, hygienic, and maintenance-friendly components into its sealing systems, GIC has significantly improved machine uptime, reduced customer support issues, and enhanced overall product life cycles.

Looking ahead, GIC continues to push the boundaries of packaging machine design, facing new challenges that demand robust, high-performance components. For manufacturers and machine builders facing similar technical requirements, Rollon’s engineering teams are available worldwide to support application analysis and component selection. To get in touch with a Rollon engineer in your region, visit rollon.com.