Higher packaging speeds with maximum seal integrity

Many machine builders and end users in the packaging industry share the same ambition:

higher production speeds, thinner (and/or sustainable) films, and perfectly sealed packaging.

With thin materials, any deviation is immediately visible. Minimal variations in pressure, profile, or temperature can lead to leaking or poor-looking packaging, instability, or unplanned downtime.

Our customer, an international OEM machine manufacturer, faced this challenge and approached us to further optimize their performance.

Together with the customer, we conducted an in-depth analysis of the process, focusing on:

– the desired packaging speeds
– the properties and tolerances of the films to be used
– the thermal and mechanical load capabilities of its sealing jaws
– the extent and type of wear on its existing cutting and sealing components

The goal was clear: to develop components that could work with the new film at high speeds with both extreme precision and long-term stability.

Based on the analysis, we developed and produced sealing jaws with profiles ground to an accuracy of a few micrometers, as well as knives with maximum sharpness and wear resistance, suitable for high-speed applications.

All these components remained thermally and mechanically stable at the desired high production capacity.

The new components were extensively tested in existing production lines, under demanding but realistic conditions. Tests were carried out on seal homogeneity at various speeds and on the temperature and pressure distribution across the seal. These tests were passed with flying colors, after which an endurance test for wear was also completed successfully.

The results were convincing: even at very high packaging speeds, the seals remained tight, uniform, and reliable.

After successful validation, our sealing jaws and knives were structurally applied in several of this customer’s machine systems. This developed into a long-term collaboration focused on continuous improvement.

Within our collaboration, we are constantly looking for further optimization in material choices and any coatings that may be applied. We contribute ideas to meet the end customer’s desire for ever-higher machine performance and structurally high and reproducible component quality.