Achieve a Perfect Seal Induction Sealing Best Practices Achieving a Perfect Seal Every Time and Raise Your Overall Equipment Effectiveness By: Enercon Industries

Understanding the process variables related to your induction sealing process is an important stepAchieving in improving your OEE (Overalla Perfect Equipment Seal Every Time Efficiency) According to Paul Zepf ofBy Zarpac: Enercon Inc Industries OEE is most simply stated as:

“Output divided by the scheduled time PerfectlyPerfectly sealed sealed products products give give consumers consumers multiplied by the normal production rate. The confidenceconfidence in inproduct product quality quality and and safety. safety. answer, in percent, looks at what should have ManufacturersManufacturers know know that that poor poor seals seals not not only only threatenthreatenbeen made consumers’ consumers’ (or packaged) perception perception versus what of of their their actually was.” (from Healthcare Packaging Oct 2008) companiescompanies and and products, products, but but also also result result in in Single piece liners often used in and beverage productproduct spoilage spoilage and and damage damage during during shipment. shipment. industry. Image courtesy of Selig. By understanding how to address and control Byinduction Byunderstanding understanding sealing variables,how how to to addresscompanies address and andcan control aspire control beverage, and vitamin applications or products inductiontoinduction achieve sealing a sealingperfect variables, seal variables, every time. companies companies can can that do not require a reseal liner in the achieveachieve a perfect a perfect seal seal every every time. time. after the foil is removed. The process of developing a perfect seal solution Single piece liners often used in food and beverage includesThe process matching of developing the cap, a perfect liner andseal sealer;solution AnotherSingle piece classification liners often is useda two-piece in food andliner. beverage This is a The process of developing a perfect seal solution industry.industry. Image Image courtesycourtesy ofof Selig.Selig. settingincludes up an matching operating the window, cap, linerand establishing and sealer; two-piece wax bonded material, which has a includes matching the cap, liner and sealer; Another classification is a two-piece liner. This is a testingsetting methods up an operating for identifying window, a good and seal.establishing setting up an operating window, and establishing two-piece wax bonded material, which has a testing methods for identifying a good seal. testing methods for identifying a good seal. backing that is usually a board, pulp or foam Matching materials bonded to the foil seal structure with a temporary MatchingWhetherMatching amaterials closure materials (continuous thread cap, child wax bond. During the induction process the wax is WhetherresistantWhether a cap, closure a closure or dispensing(continuous (continuous cap) thread thread is madecap, cap, child from child heated, melted, and absorbed into the backing, resistantPET,resistant PVC, cap, cap, PE,or or dispensing PP, dispensing PS, Gammacap) cap) is ismade (multilayer), made from from which stays in the closure for resealability. When PET,,PET, PVC, Barex, PVC, PE, PE, PLA,PP, PP, orPS, PS, metal,Gamma Gamma a perfect(multilayer), (multilayer), seal glass,canglass, be Barex, achieved. Barex, PLA, PLA, or ormetal, metal, a aperfect perfect seal seal cancan be beachieved. achieved. Choosing the right induction seal depends on the ChoosingproductChoosing beingthe the right packaged.right induction induction If seal the seal productdepends depends contains on on the the A Atwo two piece piece liner liner features features two two pieces pieces of of wax wax bonded bonded productanyproduct potentially being being packaged. aggressive packaged. If or Ifthe thevolatile product product ingredients, contains contains materialmaterial often often used used when when packaging packaging an an aggressive aggressive or or anychemicals,any potentially potentially acids, aggressive aggressive solvents, or or volatile highvolatile saltingredients, ingredients, content, volatilevolatile product. product. Image Image courtesy courtesy of of Selig. Selig. chemicals,alcoholchemicals, or acids, vinegar, acids, solvents, a solvents, protective high high layersalt salt orcontent, content, barrier backing that is usually a board, pulp or foam alcohollayeralcohol may or orvinegar,needed. vinegar, Ita can aprotective protective be sandwiched layer layer or orbetween barrier barrier The liner is the next consideration. One type is bonded to the foil seal structure with a temporary layerthelayer heat may may sealneeded. needed. film and It canIt thecan be foil be sandwiched tosandwiched prevent corrosion.between between a single piece liner, which has a backing that is the heat seal film and the foil to prevent corrosion. wax bond. During the induction process the wax is the heat seal film and the foil to prevent corrosion. typicallyA two piecea board, liner featuresfoam twoor paperpieces oflayer. wax bonded When The liner is the next consideration. One type is a inducted,heated,material melted,the often entire used and structure when absorbed packaging seals into toan the theaggressive backing, or singleThe liner piece is the liner, next which consideration. has a backing One type that is is a lip,which leaving staysvolatile nothing in product.the inclosure the Image closure for courtesy resealability. for ofresealability. Selig. When typicallysingle piece a board, liner, foam which or has a backing layer. Whenthat is packagingpackaging an an aggressive aggressive or volatile product, a a inducted,typically the a entire board, structure foam or seals paper to the layer. container When Thisbarrierbarrier type layer layer of may mayliner be beis included includedcommonly between used thein food, heat heat lip,inducted, leaving thenothing entire in structure the closure seals for to resealability. the container beverage,sealseal layerlayer andand thethevitamin foil.foil. applications or products lip, leaving nothing in the closure for resealability. that do not require a reseal liner in the closure This type of liner is commonly used in food, afterThereThere the isis foil alsoalso is aaremoved. two-piecetwo-piece reseal that combines aa This type of liner is commonly used in food, highhigh barrierbarrier retainretain linerliner withwith the induction foil. HighHigh © beverage,Enercon Industries and vitamin2009 applications or products Anotherpolyester classification film is laminated is a two-piece on the backingliner. This to that do not require a reseal liner in the closure isprovide a two-piece better wax oxygen bonded permeation material, rateswhich andhas after the foil is removed. a moisturebacking vaporthat is transmissionusually a board, rates pulp after or the foam foil bondedseal is removed.to the foil seal structure with a temporary wax bond. During the induction process the wax © Enercon Industries 2009 is heated, melted, and absorbed into the backing, which stays in the closure for resealability.

When packaging an aggressive or volatile product, a barrier layer may be included between the heat seal layer and the foil.

© Enercon Industries 2013 Removal Characteristics- (L)Clean peel does not leave any residue. (M) Welded seal’s must be destroyed to gain entry. (R) Easy entry foil seals can be punctured with a finger. There is also a two-piece reseal that combines The foil diameter is one of the most important a high barrier retain liner with the induction foil. variables in sizing the equipment. A larger High film is laminated on the backing to diameter of foil is requires a different amount of provide better oxygen permeation rates and energy to seal than a smaller one. Since there moisture vapor transmission rates after the foil are many types of foils and depending on their seal is removed. thicknesses, they can heat up differently, so it is essential to document the application’s foil type. Finally, the removal characteristics must be determined. Does the application require a clean Knowing the line speed, preferably in feet-per-minute peel where the entire liner peels away cleanly is critical. If the are traveling fast, the without leaving any residue? Does the product container will not be under the sealer as long, require a weld seal or tamper evident bond, therefore a more powerful sealer will be required. where the foil must be destroyed to gain entry and If the only information available is containers per leaving a residue on lip of container? Or, is an minute, the spacing between containers or pitch easy entry seal, where the membrane can be needs to be determined. punctured with a finger or knife, desired? Cap and geometries are additional Induction sealer considerations when selecting the optimal A number of variables need to be considered to induction sealing head for the application. There select the right induction sealer for an application. are many different types of caps and and a. b.

c. d.

Depending on the cap and container geometry different sealing heads may be required for optimal sealing efficiency. Picture above are common sealing head designs: (a)Tunnel sealing head, (b)Deep tunnel sealing head, (c)Flat sealing head, (d) Orginal All-in-one sealing head .

© Enercon Industries 2013 Setting an operating window is key to achieving a perfect seal every time. Application torque, air gap, sealer power output and line speed are the critical variables to be assessed most can be sealed with a flat sealing head. travels under the center of the sealing head However, some containers, such as those with or under a pivoted sealing head, based on sports caps, have a large gap between the top of manufacturer’s specifications. the container and the induction liner that requires a special sealing head. Step 2: Check the variables including conveyor speed, which should be a fixed value for better Additionally, the range of applications must be result (if the operation requires sealing over determined. If a wide range a containers or variable conveyor speeds ask the induction closures are to be sealed, the system needs to sealer manufacturer about a Variable Sealing be sized for the complete range of cap/container/ Control option). Ensure that closures and speed configurations. containers are compatible, examine containers and caps for defects, and verify consistent Once all the information is documented, proper closure application torque. Over 80 percent of all power supply and sealing head options can be sealing problems are related to torque issues. chosen. For smaller diameter closures, a tunnel coil is typically the most efficient. For a sports Cap Size Torque Cap Size Torque cap or yorker type cap, a deep tunnel coil is most (mm) (inch/lbs) (mm) (inch/lbs) effective. For closures over 53 mm in diameter, a flat coil is the best solution. If the application 15 6-9 53 21-36 includes a wide variety of closure sizes, an 18 7-10 58 23-40 all-in-one sealing head may be the best choice. 20 8-12 63 25-43 Operating window 22 9-14 70 28-50 Once the cap, liner, and induction sealing 24 10-16 83 40-60 equipment have been selected, setting up an 28 12-18 89 45-65 operating window for the induction sealer is the next step. An operating window enables the 33 15-25 100 50-70 optimal sealing range to be determined by 38 17-26 110 52-73 providing a record of sealing ranges that will provide no seal, a partial seal, a good seal, and 43 18-27 120 55-75 an overheated seal. This information is very 48 19-30 important because it provides the foundational The chart above shows the industry standard torque baseline for each application. requirements for successful induction sealing of various cap size. Step 1: Ensure that the orientation and alignment of the sealing head are correct. The air gap Step 3: Determine the minimum set point. Start between the sealing head and the closure by setting the output percentage at a minimum must be consistent. It is also important to make level of the induction sealer, with all of the other sure that the bottle path is controlled and variables fixed, run a single container through the © Enercon Industries 2013 sealer. Check the container for a seal. If no seal was achieved, increase output in five percent increments until there is a partial seal. Then, increase the output of the induction sealer in increments of one to two percent until a complete seal is achieved; this is the minimum set point of the operating window.

Step 4: Set the maximum set point. From the minimum set point, increase the output of the A good seal exhibits adhesion around the induction sealer by five percent until the liner or circumference of the container, no discoloration cap shows signs of overheating. Then, decrease and minimal wrinkling. the output of the induction sealer by one to two percent until overheating is eliminated. Once that is established, the maximum set point of the operating window is determined.

Step 5: Record the data. The output percentage that yields the best seal will be somewhere within the window of minimum maximum output set points. The variables that need to be recorded are the container details, the closure details, liner material details, closure application torque, conveyor speed, sealing head air gap, and the Excessive wrinkling, signs of burning or discoloration output of the induction sealer including minimum, on either the liner or in the cap indicates that either the maximum, and optimal set points within that range. output is set too high or the line speed is too slow.

Determining a good seal minimal wrinkling of the liner, and on two-piece Although there are no industry standards for liners, no darkening from overheating. induction seal integrity, there are several ways to assess seal quality. Among the more effective While many problems can be avoided by methods are wet or dry vacuum testing, shipping establishing quality control procedures on incoming the product to determine how it will respond, caps and bottles, climate controlled storage, vision systems, mechanical pressure, and shaking, and FIFO inventory, it is beneficial to have a squeezing or standing on a sealed container. troubleshooting process based on the information provided in this article in order to expedite the Characteristics of good seals that are visible to identification and resolution of any induction the naked eye include no discoloration of the liner, sealing problems. good adhesion around the entire circumference,

© Enercon Industries 2013 Induction Sealing Product Comparison

Outstanding Features Super Seal™ Super Seal™ Touch Super Seal™ Max

Sealing Capacity Low-High Medium - Very High Maximum Air cooled ü ü ü Custom sealing heads ü ü ü All-In-One Sealing Head Original Quick-set Easy changeover ü ü ü Microprocessor control ü ü ü

Safe for wash down environments ü ü ü

Validation option ü ü ü Mechanically & Electrically Mechanically & Cap inspection system option Integrated Electrically Integrated Rejection system option (integrated control) (integrated control) Display 7 Segment Touch Screen Touch Screen Computer interface option ü ü ü 365 x 384 x 240mm 462 x 200 x 391mm 812 x 300 x 432 mm Cabinet Size 14 3/8” x 15 1/8” x 9 ½” 18 3/8” x 15 3/8” x 7 7/8” 31 31/32” x 11 13/16” x 17” Operator Lock-out ü ü Recipe Management ü ü Multiple Language Support ü ü LED Light & Code Descriptive fault Faults Descriptive fault information & log Indicator information & log

Enercon Asia Pacific Enercon Industries Corp. Enercon Industries Limited Enercon Asia Pacific India United States United Kingdom India Tel: +91 4344 244303 Tel: +1 262 255-6070 Tel: +44(0)1296 330 542 Tel: +91 4344 244303 www.enerconasiapacific.in www.enerconind.com/sealing www.enercon-industries.co.uk www.enerconasiapacific.in