Package Evaluation Training 7 sealingwindow

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Package Evaluation
T i i
Training
Sealing window

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Agenda
1. Introduction
2. Transversal Sealing (TS) window
3. Longitudinal Sealing (SA/LS) window

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1 IIntroduction
1.
t d ti
Sealing window

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Introduction
Seal in Tetra Pak Packaging System
Front Panel

Transversal
Sealing
(TS)

SA

strip
s

LS

Longitudinal
Sealing
(LS)
External Sealing layer
Primer
Strip Applicator
Sealing
(SA)

Internal layer, usually PET

Rear Panel

Primer
External Sealing layer
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What is a sealing window (SW)?
Just softening/overheating PE ≠ sealing it
This statement is effective for all sealing technologies (IH; HA; US; CH)

►

A SW is the range of energy required to have an acceptable
sealing quality, starting from
a lower limit = first setting giving a good sealing decreasing the
energy the sealing gets blocked
to
an upper limit = last setting giving a good sealing increasing the
energy the sealing gets overheated
Applicable for Transversal sealing (TS), Longitudinal sealing (LS), Strip
Applicator (SA), PullTab (PT),…

►

The optimum is defined by the medium value of the range.

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What is a sealing window (SW)?
Example of LS sealing, hot air

Sealing window is

from 180 ◦C to
290 ◦C, medium
value is 235 ◦C

Medium setting, 50%
is recommended to
use in production

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SW: When is it required?
►
►
►
►
►
►

New filling machine installation
New production capacities
New type of product (different viscosity, %fat, fibre, etc…)
Product temperature change (impact on TS)
Trouble shooting
Etc…

Basic Requirements:
1.
2.
3.

Filling Machine perfectly set following MM
Test methods
Trained personnel

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2. Transversal sealing
window
i d
Sealing window

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Transversal seal : Induction heating

Sealing jaw : Inductor
Pressure jaw : Dollies, Cutting rails, Knife, Spring, Rubber Bushing
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Transversal seal evaluation

Tearing

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Transversal seal evaluation
Dissolving

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Transversal seal evaluation
Dissolving - Heat pattern evaluation

Note:
For 6 mm fin package
(TBA 80,100B, 125S);
B-measurement is
acceptable when > 0
mm

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Transversal seal evaluation
Dissolving - Red ink tightness

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TS sealing window
TPIH 2000 - 2500
The setting
g range
g determined by
y the test is only
y valid in the
conditions during the test and not as general working range
for the filling machine.
► If any comparison test need, it is necessary to run at the test
same occasion and with the same conditions.
► Filling machine must set according to MM and EM, the
settings of the jaw system, e.g. parallelism, are an important
parameter to assure the final result of the activity.
► Verify the conditions of the cutting rails and inductors,
inductors mount
new dollies.
► Check the cooling water flow through the inductors (for two
jaws machine).
►

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TS sealing window
Test Execution - General
After machine ready in Production state, make a preliminary
test to find the power setting of the TPIH unit for
cold/blocked seal.
► Run machine with the found value for about 5 minutes in
order to stabilize all temperatures.
► Run at least 100 packages before collect packages sample.
► Then increase the power setting by 10 scu or 25 watt for
every trial until the upper limit found (plastic lumps,
overheating swinging package).
overheating,
)
►

Note: Increase power setting can be 20 scu or 50 watt on middle
value but not at the lower of upper part.

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TS sealing window
Test Execution – 2 jaws machine
► At

each setting take out 10 packages (5 LH and 5 RH)

► Evaluate 2 LH and 2 RH packages (total = 4 packages per
setting) immediately with the stretch pliers, note the seal
quality in the test report
►Once

the range is defined, take 1 LH and 1 RH (total = 8
packages) at the lower, middle, ¾ and highest setting to be
dissolved
Highest
g
setting
g
3/4 setting
Middle setting

Lower setting
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TS sealing window
Test Execution – Chain machine
► At

each power setting take out total 20 packages (2
packages per link). Make sure each package is marked with
link number.

► Evaluate 4 packages immediately with the stretch pliers,
note the seal quality in the test report
► Once the range is defined, take out 1 sample per link (total
=10 packages) at the medium setting and evaluate
immediately with the stretch pliers to verify the uniformity of
th sealing
the
li quality
lit among allll th
the lilink.
k
►Once the range is defined, take 1 sample per each link (total
= 40 packages) at the lower, middle, ¾ and highest setting to
be dissolved.

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TS sealing window
Documentation
Record P-order and reel no.
Record Filling machine information
Record product and temperature
► Record all settings
► Attached form as example
►
►
►

Microsoft Excel
Worksheet

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3. Longitudinal
S li window
Sealing
i d
Sealing window

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Longitudinal seal (LS)

SA

LS
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Longitudinal seal evaluation
Heat distribution zonoscope

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Longitudinal sealing evaluation
Tearing

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Longitudinal seal evaluation
Ink injection to air gap

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Longitudinal seal evaluation
Ink injection to air gap – Channel deviation

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LS sealing window
Hot air/Induction heating

The setting
g range
g determined by
y the test is only
y valid in the
conditions during the test and not as general working range
for the filling machine.
► If any comparison test need, it is necessary to run at the test
same occasion and with the same conditions.
► Verify conditions, alignment and setting of hot air
elements/inductor, spring pressure according to MM, mount
new LS pressure roller.
► Check the overlap dimension and overall forming of the
package produced, overlap and forming should be on
package basic condition.
►

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LS sealing window
Test execution
► After

machine ready in Production state, make a preliminary
test to find the power setting of the lower limit by tear down
method.
► Let the filling machine produce for 10 minutes before test
execution
►

Run at least 100 packages before collect packages sample

Then increase the power setting by 10 scu/C or 25 watt for
every trial until the upper limit found (blistering/swing packages)
►

► Hot air - Each setting read the temperature and air pressure
and note in the record, adjust pressure according to recommend
setting in MM when increase temperature.

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LS sealing window
Test execution, cont…
► At

each setting take out 14 packages for evaluation

►Evaluate

by manual tearing 4 packages for each setting

►Evaluate

10 packages each setting by red ink injection to

air gap, record the result in the test report

► Use zonoscope to check heat distribution, constant heat
distribution along the seal length. For lower setting, heat
distribution should >2 mm from strip edge
edge.
► Induction heating, for upper part, the length of wrinkle
must be < 15 mm.

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LS sealing window
Documentation
Record P-order and reel no.
Record Filling machine information
Record product and temperature
► Attached form as example
►
►
►

Microsoft Excel
Worksheet

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E d
End
Sealing window

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