Companies are under constant pressure to reduce operational costs while obtaining the best sealing quality possible. Thus, manufacturers’ demands come down to two main factors, efficiency and quality.
This is why sealing machine manufacturers, such as Levapack, are often asked for resolutions that permit the utilization of cost-efficient packaging seals while also guaranteeing tight and long-lasting packs — all as segments of a durable packaging process that reduces waste and downtime while providing excellent product protection.
Here are some of the things you should know about the overlooked significance of sealing technology in manufacturing.
How the Sealing Process Works
To make a flow-wrapped package, the packaging film is formed into a tube through a length seal. Then, two cross seals enclose the product fully, making the package tight. It is general knowledge that sealing is just a combination of pressure, temperature, and time.
Heat sealing fuses the seams under pressure at temperatures ranging up to 250°C. In contrast, in cold sealing, the only pressure is applied to make a seal. Temperature and time are not that essential here. In ultrasonic sealing, the sealing film is mechanically cold loaded in the ultrasonic frequency range where it will melt. Each of these sealing technologies needs appropriate films with suitable properties to produce the desired result.
These sealing approaches are implemented in practice using various mechanical concepts:
- In the rotating sealing technology, the sealing is presented by the mutually counteracted sealing pressure jaws, with the help of CNC robot arms. Thus, the purely rotating seal movement is mechanically the fastest innovation technology with a short sealing time drawback.
- However, time is literally of the essence when it comes to the most critical factors in the flow-wrapping process. This is especially correct for the sealing of cross seams in ultrasonic and heat sealing. This is why several sealing manufacturers offer various sealing movements, extending the sealing time to a maximum without slowing down the rest of the packaging line.
- In long-dwell sealing applications, the sealing jaws adhere to an eccentric motion, which permits sealing up to 40 times longer compared to rotary sealing, producing hermetic packages. Still, this sealing method has a mechanical limitation of 40 meters of film per minute.
- Amplified heat sealing or AHS, is the latest innovation in sealing technology. The rotary sealing machine moves with the film, making a sealing time that is four times longer compared to the static rotary station’s sealing time.
In addition, with an achievable film rate of 70 meters per minute, this technology is located right between long dwell and rotary sealing, incorporating the perks of higher sealing integrity at higher speed rates.
The Main Challenges for Manufacturers About the Sealing Process
Manufacturers are faced with the hurdle of juggling product quality with efficiency, speed, and cost. Note that there are no two projects that are the same, since many variables can affect a particular process. This includes overall speed, product consistency, industry regulations, speed variations, packaging style, film types, climate, and shelf life. Furthermore, waste has to be kept to a minimum.
For instance, the CNC robot arms used for film packaging can be a factor. This is why it is essential to check all aspects, like if the robot is well-maintained, or it has reached its limit, to avoid waste or downtime. Or maybe you need additional robotic arms to help in the production floor. You better check out the CNC robotic arm price in the market and see what’s hot today.
With all of these parameters to consider, applying the right technology for a specific product and production process is essential.
Differences of Technologies in Terms of Various Applications
Generally, chocolate products are sensitive to heat, and manufacturers require high line speeds. This is why they are wrapped in films suitable for cold seals.
On the contrary, goods packed in a jar, bottles are traditionally wrapped in films fitting for hot seals. This is due to their typically slower speeds than chocolates, and the products are not sensitive to heat. We see that manufacturers are under pressure to increase the pace for their food in a jar line. Then there’s the brand sealing for bottle decoration ideas to beautify the product container and make it distinguishable from its competitors.
The Most Important Considerations to Sealing Films
Several factors should be considered, including finding suitable films for sealing at higher speeds, balancing quality against cost, selecting the right jaw profile for the film used, and finding a film that suits the sealing method. Fortunately, innovative technologies now allow the use of more cost-effective alternatives where conventionally expensive films were needed. For instance, amplified heat sealing can be done with less expensive heat sealing films.
Sealing technology is a crucial part of production facilities. Find a business partner who has expertise across all sealing technologies. They will guide you to the solution that will give product manufacturers the best result, both quality and efficiency.