Knowledge Center: P3 Solutions Blog

Technical posts and videos from Greener Corporation that help you solve problems and optimize your entire packaging process on horizontal flow wrappers and vertical form/fill/seal baggers. Learn how to improve:

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Blog de Soluciones P3 y “Segmentos Técnicos” en Video

El Blog de Soluciones P3 de Greener Corporation presenta soluciones de Partes, Procesos, y Personas que integran todo el proceso de empaque en Envolvedoras Horizontales y Envasadoras Verticales:

Diseños de partes innovadores para Cortar, Sellar y Formar
Métodos de instalación y ajuste
Mantenimiento preventivo
Resolución de problemas

Suscríbase para recibir actualizaciones periódicas sobre la optimización del rendimiento del empaque.

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 Envolvedoras Horizontales    Envasadoras Verticales  •  Corte  •  Sellado  •  Formado  

Case Study: New Film Trials

In this blog post and Tech Bites video we consider a case study on running successful new film trials by optimizing parts designs, machine set-up, and operating procedures according to new film specifications.

A corporate engineer for a large bakery operation teamed with a packaging film converter to specify a new film structure for their product line of cookies. The product was packaged on multiple horizontal flow wrappers at three different bakeries.

Quality End Seals_Greener Corporation

If the new material could maintain the current levels of seal integrity, quality appearance, and productivity, it would reduce material costs by thousands of dollars per month on each machine and produce significant total cost savings.

Case Study_Film Trial_total cost savings


Film Trial #1

The project team gathered for a trial run, where the new film was installed on one wrapper by the machine operator and line mechanic. They relied on the familiar adjustment settings, crimpers, and other tooling utilized for the original film, but seal quality tests of trial packages showed an unacceptable rate of end seal leaks.

With this unfamiliar film structure, machine adjustments did not improve seal integrity and caused additional problems:

  • Temperature increases distorted the package.
  • Attempts to reset the crimper clearance crushed and split the end seal and caused cutting issues.

horizontal flow wrappers_technical support_Greener Corporation

end seal leakers at fin seal and corners

Leakers

end seal distortion from excess heat

Heat Distortion

end seal damage from excess pressure

Excess Pressure


Film Trial #2

After this unsuccessful first trial, the project leaders invited Greener Corporation to join their team. Greener reviewed the trial procedures and results, including sample packages, and determined that the serration pattern of the existing crimpers was not appropriate for the new film. We recommended and were asked to manufacture one set of crimpers with a new design that would produce optimal results.

match serration design with new packaging film

Our technical service manager, who had experience working with similar film structures, helped to install the new crimpers, make required machine adjustments, and provide technical support for a second trial of the new film, which efficiently and consistently produced high quality packages with excellent seal integrity.

Crimper and Sealing Jaw Serration Pattern_designed for specific films_Greener Corporation

horizontal flow wrapper_new film trials_Greener Corporation

Quality End Seals_Greener Corporation

Once implemented, the project provided the expected savings and some additional, unforeseen benefits:

  • Machine operators and mechanics required fewer machine stoppages to make adjustments, and found it easier to consistently meet package quality standards.
  • Bakery and corporate managers reported higher production rates, reduced waste, and improved seal integrity and package appearance compared with the original film.

Through a collaborative, team-based approach, the project was a great success.

For assistance with your new film trials and other projects involving horizontal flow wrappers and vertical baggers, contact Greener Corporation. We develop and deliver solutions worldwide.

horizontal flow wrapper_project development_Greener Corporation

vertical form fill seal bagger_project development_Greener Corporation

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