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:

  • Part Designs for Sealing Jaws, Knives, Formers, & more
  • Problem Solving & Preventative Maintenance
  • Training
  • Quality Improvement & Cost-Saving Projects
P3 Solutions Blog

Publicaciones técnicas y videos de Greener Corporation que lo ayudan a resolver problemas y optimizar todo su proceso de empaque en envolvedoras horizontales y envasadoras verticales de formado / llenado / sellado. Aprenda a mejorar:

  • Diseños de piezas para mordazas selladoras, cuchillas, formadores y más
  • Resolución de problemas y mantenimiento preventivo
  • Entrenamiento
  • Proyectos de mejora de la calidad y ahorro de costos

Forming & Sealing on Vertical FFS Baggers: 6 Key Design & Set-Up Principles

Discover 6 key design and set-up principles that will help you identify the source of forming and sealing problems and develop solutions. Learn how to optimize the performance on your formers, sealing jaws, and your whole packaging process.

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.

1. Product Flow

Let’s start at the beginning. Problems occur most often when the product is:

large in relation to bag size
inconsistent in size or shape
lightweight
oddly shaped
or with rough outer surfaces

Bottlenecks occur when product strings out as it moves from the inlet chute into the narrower confines of the forming tube. In extreme cases individual product “charges” can bridge together. These product flow issues slow down production speeds, create blockages, and cause leakers when product gets trapped in the seal.

Flujo de Producto en Envasadoras Verticales de Formado-Llenado-Sellado

On forming tubes with integral cones the product dose is slightly staggered, so it passes through the bottleneck faster and stays more compact.

Tubo de formado con conos integrados en Envasadoras Verticales

2. Forming Set Design

Forming sets should be designed according to your product, package design, machinery, and film specifications. Make sure that this optimal design is accurately and consistently replicated when you order replacement parts or specify formers for multiple machines, lines, or locations.

Producto para envasadoras verticales de formado-llenado-sellado

Diseño de paquete y formador para envasadoras verticales de formado-llenado-sellado

Diseño de Formador para envasadoras verticales de formado-llenado-sellado

3. Roller Position

Machine adjustments are also critical for producing quality packages. Misaligned film rollers prevent the film from making full contact with the forming collar, causing wrinkles, creases, and package distortions that reduce shelf appeal and cause seal problems.

Wrinkled package from vertical FFS bagger

4. Film Drive

Poor package quality is caused by film drive issues such as belt adjustment and forming tube alignment.

Twisted package from vertical FFS bagger

5. Former Wear and Damage

Wear or damage to the former lip or wing can also distort the package.

Package distorted by worn or damaged former on vertical FFS bagger

6. Sealing

By fine-tuning your forming and filling operations you will improve both package appearance and seal quality.

Leakers
The end seals on packages produced by vertical baggers typically vary in thickness. Most have a lap or a fin seal, and some are designed with gussets. Unintended wrinkles or pleats may, at times, be unavoidable. Leakers, when they occur, often follow channels at the intersections between two and multiple layers of film and at the corners.

Fugas en las intersecciones entre dos y multiples capas de material de envoltura

Sealing Jaws
Sealing jaws must transfer enough pressure and heat to seal across these channels without crushing, cutting, or distorting the end seal.

El exceso de presión de las mordazas puede aplastar o dividir fácilmente el sello.

Excess pressure from sealing jaws can cut the package

Excess heat from sealing jaws can damage the seal and cause leakers

Pressure
In order to create uniform sealing pressure, the serration profile of your sealing jaws should be designed according to your package specifications, machinery, and running conditions.

Patrón de Dentado de Mordazas y Material de Envoltura

Heat
Sealing jaw temperatures are often increased to improve seal quality, but this can create hot spots that overheat and distort the package.

Jaws manufactured from Dura-Therm material provide more responsive, consistent heat transfer across the package to help seal off channel leakers without overheating the film.

Resena_termica_mordaza_de_acero y de_mordaza_Dura-Therm

Wear and Damage
Jaws that are worn, damaged, or contaminated with product also create inconsistent pressure and heat transfer that cause seal problems.

Mordazas que estan desgastadas o dañadas causan problemas de sellado.

To learn more about forming and filling on vertical baggers, contact our partner, Kenray Forming. They provide remote training and consultancy to help you optimize your packaging operations.

Kenray Forming_sets formadores para envasadoras verticales

For more details on sealing consult the wide variety of Greener “Tech Bites” posted here on our P3 Solutions Blog, or contact Greener Corporation. We develop and deliver solutions worldwide.
Blog de Soluciones P3_Soluciones para Envolvedoras Horizontales & Envasadoras Verticale

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