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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Analyzing Sealing Jaw Carbon Impressions to Troubleshoot Problems on Flow Wrappers & Vertical FFS Baggers

In this Greener Tech Bite we analyze six sealing jaw carbon impressions and explain how each was used to troubleshoot problems on flow wrappers or vertical form fill seal baggers. Read more

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Standardizing Knives & Sealing Jaws on Flow Wrappers & Vertical FFS Baggers


Do you run different makes or models of flow wrappers or vertical form-fill-seal baggers? If you do, you probably use a variety of knife and sealing jaw styles that you need to keep in stock. With different knife or sealing jaw designs, the seal quality and appearance of your packages may vary, depending on which machine, line, or facility produced them. Read more

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Product Presentation and Package Formation on Horizontal Flow Wrappers


The ultimate quality of the packages produced on horizontal flow wrappers requires a complex series of events to form and fill each package and move it through the packaging process. In the following post and “Tech Bites” video we explore the many steps that occur before and after packages are cut and sealed—from the product feed and film unwind through to the discharge belt—that must be fine-tuned to optimize seal integrity, package appearance, and productivity.
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Product Flow Issues on Vertical Baggers

Refinements and Forming Set Designs that Boost Productivity and Package Quality

Improve Product Flow on vertical baggers_Greener corporation_Kenray FormingOptimizing packaging performance requires fine-tuning of the entire product flow process—from the way product is distributed into the measuring system through to the filled, sealed, and cut bag or pouch.

Symptoms of product flow issues on vertical baggers include downtime from product blockages and poor end seals and cutting problems due to product contamination of the sealing jaws and knife. Considered in isolation, as one-time incidents, each problem may only cause a relatively short period of downtime and a small amount of product and film waste. But when the cumulative impact of product flow issues is considered over time, the costs can mount. Read more

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Solving Cutting Problems on Flow Wrappers During Production

When cutting problems occur on horizontal flow wrappers during a production run, what are the best procedures to get packaging lines up and running again and to keep them running? Minimizing downtime, producing consistent quality packages, and managing costs require a balanced approach that includes:

  • Knowing which “quick-fix” adjustments will get knives cutting without causing additional problems and downtime. (Faster and easier is not always the best solution.)
  • Broad-based, P3 Solutions that consider the entire packaging process to:
  • Understand how each adjustment affects the whole system.
    Eliminate procedures that don’t work.
    Diagnose and correct the ultimate causes of problems. (Many issues stem from a combination of factors.)
    Implement solutions that help prevent cutting problems from occurring in the first place and help you Pursue Zero.

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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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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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Keeping Your Packaging on Track

Side to Side Misalignment

Side to Side Misalignment

Even experienced users of forming sets can, over time, become conditioned to accept the hidden costs and preventable constraints of their packaging equipment. As with all waste, however, careful diagnosis of the root causes will lead to implementation of effective solutions.

One such root cause is forming tube misalignment. This can occur if the forming set has been accidentally mishandled and damaged or if the forming set has not been properly designed and fabricated in the first place. Read more

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