Form Fill and Seal Packaging Solutions

Efficient FFS and VFFS packaging films manufactured to your exact specifications. Airtight protection for food manufacturers and agricultural applications from warehouse to shelf

Bespoke Form Fill Seal Film Manufacturing

Tailored to Your Production Line

We manufacture form fill seal films designed to fit your existing production lines, with custom dimensions and volumes to suit your specific requirements. Our bespoke approach ensures simple installation and efficient production line integration.

Seamless Production Integration

Our technical team works directly with you to ensure compatibility with your existing equipment. We provide material specifications, sealing parameters, and ongoing support to optimise your packaging line performance and minimise waste.

Why Choose Polystar Form Fill Seal Packaging

Airtight Protection

Our form fill seal packaging is designed for loose products requiring airtight conditions, providing a practical and efficient packaging process. The strong material ensures your packaging stays airtight throughout the transport and storage process.

Quality Assurance

By ensuring the quality of containment with no rips or tears in the packaging, our FFS films reduce the likelihood of contamination and returned products, increasing confidence in the quality of your products.

Perishable Product Protection

Ensures perishable products reach customers in the best quality. Our form fill seal packaging maintains product integrity from warehouse to shelf, critical for food manufacturers and agricultural applications.

Versatile branding

Polystar’s FFS films can be printed up to 6 colours. This supports simple handling marks, product identification, and brand visibility on outbound loads.

Industries We Serve

Food Manufacturers

Our food-grade form fill seal films provide essential protection for fresh, frozen, and dry food products. From vegetables and fruits to bakery items and confectionery, we ensure your products maintain freshness, quality, and compliance with food safety regulations throughout the supply chain.

Agricultural Market

Specially suited for the agricultural sector, our FFS packaging is designed for loose products requiring reliable containment and protection. Strong material construction ensures products stay secure throughout transport and storage.

Frozen Food Applications

Our form fill seal packaging is engineered for frozen food packaging requirements, providing the airtight conditions essential for maintaining product quality in cold chain logistics.

Many More

Upgrade to Tristar for Enhanced Performance

Reduce your form fill seal costs by up to 20% with our exclusive Tristar™ material. This unique blend of three advanced polymers produces a strong, tear-resistant polythene that delivers equivalent strength from a lighter weight film.

Our co-extruded Tristar™ technology offers unrivalled dart impact and tear resistance. The lightweight nature means fewer production costs, which translates into direct savings for our customers, typically up to 20% less than standard polythene.

Tristar™ is engineered to reduce your polythene consumption by up to 30%, helping you save both costs and reduce your carbon footprint. This exclusive material from Polystar is only available through us, giving you access to next-generation packaging innovation.

Our Accreditations

BRC
Acredited

Send Your Enquiry To Polystar Plastics Today

Growth And Expansion

Polystar Plastics Ltd continues aggressive expansion with cutting-edge equipment, facility upgrades, and prestigious industry awards that underscore its leadership in polythene manufacturing.

Key Investments

Polystar has continued to make substantial investments in state-of-the-art extrusion technology, installing an additional six new lines in recent years to produce high-performance films for a wide range of markets. In 2024, we invested in a new Expert six-colour printing press capable of printing widths of up to 2.3 metres. In 2025, we designed and built a new warehouse facility with a capacity of up to 10,000 pallet spaces. As a customer-centric company, we remain committed to investing at a rapid pace to support growth and innovation.

Awards & Recognition

Polystar earned Processor of the Year at Plastics Industry Awards 2024 (November), following Best Business Initiative (2022) and COVID-19 Business Hero (2021), plus shortlisting for Manufacturer of the Year (over £25m, Made in the South East Awards 2020). The Times recognised sustainable PCWflex innovations, affirming commitment to excellence in growth, technology, and environmental stewardship.

Growth Impact

Enhanced infrastructure accelerates order fulfillment, technical film output, and sustainability via 100% recycled material processing without quality compromise, a BRC certified facility producing a comprehensive range of technical and industrial films which also included conversion and printing. These advancements deliver bespoke solutions faster for UK/Europe clients, from independents to global brands.