The switch to recyclable mono-material packaging brings new challenges. Whilst these materials contribute to more sustainable packaging solutions, they can also be more susceptible to cuts, tears and damage during the packaging process.
An international food manufacturer encountered precisely this problem. During packaging, the mono-film was damaged at the point where the seal transitions into the part of the packaging containing the product. This created the risk that the packaging would no longer be completely airtight.
The customer was therefore looking for a solution that would resolve the film issue and improve the reliability and stability of the sealing process.
The existing sealing jaws exerted too much pressure on a critical section of the packaging. Combined with the properties of the monofilm, this led to damage to the film.
It was important for the customer to:
Based on an analysis of the application and the operation of the sealing heads, we modified the geometry of the sealing jaws. These modifications were specifically tailored to the properties of the mono-film used.
After a full month of production using the new sealing jaws, the results were convincing. The customer reported a temperature reduction of approximately 30–35 °C compared with the original sealing jaws. Furthermore, there was a significantly reduced need for manual adjustments during production.
The customer rated the performance as excellent and indicated that they were very satisfied with our new sealing jaws.
This case study illustrates that the switch to recyclable packaging materials affects both the packaging material itself and the way in which sealing is carried out. This is because mono-film can be more susceptible to cutting and tearing. Consequently, the geometry of the sealing jaws has a major influence on the final packaging quality.
By tailoring the radius, profile geometry and edges of the sealing jaws to the specific application, damage issues can be prevented and the sealing process optimised.
The result: a more reliable seal, fewer manual corrections and a lower sealing temperature.
This successful solution has now led to further steps. In addition to upgrading the sealing jaws on the existing machine, consideration is being given to a similar packaging machine within the same factory. This offers the opportunity to apply the knowledge gained further and to optimise sealing performance there as well.
Every packaging line and every packaging material places different demands on the sealing process. That is why a good solution does not start with a standard component, but with an understanding of the entire application.
In this case, it was precisely the combination of technical analysis, adapted geometry and knowledge of monofilm packaging that made the difference.
Delba is also happy to work with you to find solutions to complex challenges relating to sealing and packaging materials. Our experts have extensive knowledge and experience and will work with you to find the right solution for your specific application.
Are you facing a challenge in your production process or encountering problems with sealing?
Please feel free to contact us. Our experts will be happy to work with you to find a solution.
You can reach us at sales@unspi.com or on +31(0)55 208 2400.
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