Package Diagnostics: Case 1 – Sealing Jaw Design


This Greener Tech Bite is the first in a series of case studies on the Package Diagnostic Process.

When we work with clients, sample packages provide vital diagnostic clues for troubleshooting problems on flow wrappers or vertical baggers. And even when clients don’t report problems, we use sample packages to help them discover and implement improvements that they may have overlooked—from new knife, sealing jaw, and former designs to machine adjustments that optimize the whole packaging process.
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Case Study: Resolve Cutting & Sealing Problems with Standard Operating Procedures & Training

One of Greener’s Technical Salespeople discovered that knife purchases by their customer had grown by 35% over the past year, at an additional cost of nearly $10,000. It seemed unlikely that additional production had accounted for all of this increase, which indicated to him that the customer could be experiencing problems on their horizontal flow wrappers.
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Forming & Sealing on Vertical FFS Baggers: 6 Key Design & Set-Up Principles

This Greener Tech Bite, with the help of our partner Kenray Forming, explores six key design and set-up principles to help you identify the source of forming and sealing problems and develop solutions for quality packages. Read more

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Repeatable Quality and Productivity



In this blog post and Tech Bites video we outline solutions to achieve repeatable quality and productivity on horizontal flow wrappers and vertical baggers across all production shifts, multiple packaging machines, and different plant locations.
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Sealing Over Extra Layers of Film at the End Seal (part 4 of 4): Optimizing Crimper & Sealing Jaw Design

There is no one-size-fits-all solution for the design of crimpers and sealing jaws on horizontal flow wrappers and vertical baggers; they should be specified according to the packaging film, products, and conditions of your packaging operation.

This post, the last in our four-part series, reviews design options for crimpers and jaws. The optimal combination of serration patterns, materials, and special features can dramatically improve seal quality and productivity when sealing across extra film layers at the end seal. Read more

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Troubleshooting Extra Layers of Film at the End Seal (Part 1 of 4): Refining and Eliminating Wrinkles and Creases on Horizontal Flow Wrappers

Varying thicknesses of film at the end seal can cause sealing problems, especially at the transition point between two and four layers created by the fin seal, gussets, wrinkles and creases, as well at the corners. Applications of pressure and heat (if applicable) must be great enough to cause the sealant layer to flow into and seal off these voids. Excess pressure can easily crush or split the end seal, while overheating distorts the seal and can cause poor hot tack, where the film springs back open, or “moons,” before the seal can set.

Package Quality Issues_Greener Corporation

The operating window for creating quality seals can be elusive, resulting in packages that leak, are distorted, and have little appeal to consumers.

An important step in troubleshooting these issues is to eliminate unintended wrinkles and creases. This post, the first in a four-part series, will examine this process on horizontal flow wrappers; Part 2 considers these issues on vertical baggers.

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Optimizing Knife and Anvil Set-Up on Horizontal Wrappers

Set-up procedures for knives and anvils can vary according to the make and model of the packaging machine, knife adjustment style, and other factors. There are, however, some general principles that make these adjustments more effective and efficient, reducing downtime and parts costs.


Diagonal Zig Zag Knife for Horizontal Wrapper_Greener Corporation
  Optimize Knife Design

  • Knives ground on a diagonal, or bias–whether they have a zig zag or a straight cutting edge—require less pressure to cut so they are easier to set up and typically last longer.
  • Zig zag knives with smaller (more) teeth are also easier to set up and provide longer life.

  Set Up the Crimpers First

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HEAT: Improving Seal Quality and Consistency

For heat seal applications, each packaging film structure has a Seal Initiation Temperature (SIT), at which the sealant layer is heated enough to flow into and seal off gaps in the end seal and provide a minimally acceptable seal, and a Maximum Temperature, beyond which the film distorts, fractures, or has inadequate hot tack (seal strength and integrity while the seal is still warm). The temperature range between the minimum and maximum is the film’s Operating Window.

For a number of reasons, regulating heat is not as straightforward as simply adjusting the temperature setting within the operating window for the film you are running.

 The sealing face of crimpers and sealing jaws is often hotter in the middle than at the ends, where heat dissipates more quickly. These inconsistencies are readily apparent in the thermal profile shown below:

Stainless Steel Crimper Thermal Profile

Stainless Steel Crimper Thermal Profile

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