Troubleshooting Checklist for Horizontal Flow Wrappers

This Greener Corporation “Tech Bite” provides a Troubleshooting Checklist for working with us to solve packaging problems on horizontal flow wrappers. Answers to the checklist questions will allow us to help define your problem, determine the causes, and develop solutions that restore package quality and productivity.
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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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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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Troubleshooting Extra Layers of Film at the End Seal (part 3 of 4): Optimizing Set-Up & Adjustment of Crimpers, Sealing Jaws, & Knives

The first two parts of this series explored the potential problems created by end seal wrinkles and creases and ways to eliminate or reduce them on horizontal flow wrappers (Part 1) and vertical baggers (Part 2). In some situations wrinkles or creases are unavoidable, and, even without those issues, most packages have the inevitable transition between multiple film layers created by either a fin or a lap seal.  This can make it more difficult to achieve quality seals, and attempts to do so can lead to additional issues:

 Excess pressure can easily crush or split the end seal.

 Overheating distorts the seal and can cause poor hot tack, where the film springs back open, or “moons,” before the seal can set.

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

This post reviews some of the detailed solutions in Greener Corporation’s Knowledge Center that will help you seal over extra layers of film at the end seal by refining the set-up and adjustment of crimpers, sealing jaws, and knives.

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Troubleshooting Extra Layers of Film at the End Seal (Part 2 of 4): Refining and Eliminating Wrinkles and Creases on Vertical Baggers

Varying thicknesses of film at the end seal can cause sealing problems, especially at the transition points of multiple film layers created by the fin or lap seal, gussets, wrinkles, creases, and at the corners. Applications of pressure and heat must be great enough to cause the sealant layer to flow into and seal off these voids.  However, 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_vertical baggers_Greener Corp

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

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Case Study: Packaging Material Cost Reduction

Project Goals

The corporate engineering department at a large, international company commenced a project to reduce material costs for a variety of products that are individually packaged on horizontal flow wrappers. Greener Corporation was invited to participate in a series of meetings that defined the project’s initial goals:material cost reduction_Greener Corporation

  • To reduce the cut-off length for each package by reducing the overall seal width, thus allowing the product envelope to remain unchanged.
  • To achieve material savings without degrading seal integrity or productivity levels.
  • To achieve a project payback period of twelve months or less.

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