Process Validation for Induction Sealing
It is an all time recommendation to have process validation for induction sealing to safeguard the sealing performance due to many variables that could easily change the performance of an induction machine.
A slight change in the induction machine sealing power setting, product conveyor speed, guide rail settings, sealing head angle or sealing head height can all have significant influence on the amount of energy the induction seal will receive; resulting in failed seals.
Visual Inspections: Induction Sealing Process Validation
Even the most competent and capable operators on your production shifts have to rely on opening product to make visual inspections and perhaps a very good memory of how warm the cap should feel immediately after passing through the sealing head.
Manual validation is more anecdotal than value based “validation” of your induction sealing process and machine set-up. The LinePatrolman™ range provides you with that numerical and repeatable process validation measures. The measure is a calibrated reading to record the energy that would be transferred to products passing through the machine.
Some Things to Look for in a Good Seal:
- Correct Settings – An experienced operator would know to look for a concentric heat pattern in the foil; by holding the foil to a light source at the correct angle he would see a smaller circle where material has not been affected by heat. This means the seal has heated from the outside inwards in an even pattern; hence an even seal.
- Overheating – there are a number of factors to show if there has been overheating including – visual discolouration of one or more layers of the induction foil, bubbling or creasing, a flattening of the bottle neck, melting of a backing resealing foam (when present).
- Uneven heat sealing –The foil can look well sealed but an uneven heat seal can result in areas of the seal being too firmly “welded” or very lightly welded making the seal likely to fail with a little pressure on the side walls of the bottle/container.
How to Improve Your Induction Sealing Process with the Patrolman™ range
If you have doubts that you will always operators trained or experienced enough to cover what is required for a reliable visual process of validation for induction sealing, then there is the simple option of a LineMaster™ which has no more controls than a reset button.
This unit needs no programming and simply provides an integrated count of the energy seen by the testing cell passing down the same path as the products.
A reason that many need an induction sealing measurement is because the energy transferred by an induction sealing machine to the foil of an induction seal within a cap is a time and position dependent process. The LinePatrolman™ range are unique process validation tools that will pick up variations in energy transfer in what may look like an identical set-up to the last time an induction machine was run. This tool takes way the guess work on what energy is being transferred and provided operator confidence that the machine is set to the best it can be set.
Caps and Closures
As we deal with so many cap manufacturers we are able to source and supply you with the cap and cap lining material combination you are looking for without the need to separately supply you with cap lining material. The caps are supplied from cap manufacturers for whom we have an established trading relationship.
These cap manufacturers will almost always sell through third parties and we have qualified with many cap manufacturers to be that third party. We insure the pricing we supply is equal to or better than if you had gone to other third parties or EVEN the cap manufacturer themselves.
Our knowledge and involvement in the supply of Cap Lining Material, Lining Inserting equipment for the cap manufacturers and induction sealing equipment for the end user means we can help source “get-it right first time” combinations of caps with cap lining material and supply at very competitive pricing.
Material Liner is what we call that piece (or pieces) of what looks like paper inside product caps. It is also referred to as induction foil, induction sealing material, foil seals and induction seals among others. Many people are unaware of the purpose they serve to the product aside from being a protection seal or a tamper proof seal.
Material Liner Purpose
Material liner within caps can be one piece or two pieces depending on the expected purpose of the lining material.
Single piece cap liners are often present in smaller sized containers in which the product is likely to be consumed after opening. Its packaging is regarded as being one time use packaging. In this instance, the liner functions as protection until the product is opened. No other material is left inside the cap.
Larger packs or bottled items are not likely to be completely consumed right after opening. The consumer is more anticipated to reclose the container and store the product. The caps used on these conditions have demands for caps that reseals effectively. Upon close examination, the caps used on these kinds of merchandise have laminated foam within. This lamination enables the cap to reseal the container upon closing to maintain product freshness. The laminations within the cap as well as the removed tamper evident seal on the product are referred to as two-piece cap liners.
Deciding on the best components and structure of your foil seal is essential to guarantee the proper amount of protection for your merchandise. We can help you in selecting the type of material as well as the construction suitable to your application.
We have induction sealing materials available in many variants to fulfil almost any standard or individualized product packaging requirement which are safe and meet the strict specifications set by the Food and Drugs Authority.
Effective for products that must be kept free from contamination, oxidation and moisture, tamper evident hermetic seals are best suited for use in the following production:
- Food & Beverage
- Organic solvents and products
- Other products
Induction foils are generally supplied to the closure manufacturers. Developed over 35 years ago, induction sealing, in the beginning, was designed to eliminate leakage of chemicals from plastic bottle caps. At present, this method works extremely well with most style container and closure.
Induction Sealing Process
The caps are supplied with an induction foil waiting to load into the capper. The container is then filled and capped, using the caps that are pre-lined with the induction foils.
The capped container is then transported down the conveyor line and travels underneath the induction sealing head. The electromagnetic field generated by the sealing head penetrates the cap and the aluminum foil layer. When the field permeates the foil, it causes an electrical current which melts the liner’s sealing film. The foil cools down as it leaves the induction field causing the heat seal film bond to the container. Once the cap is removed, the aluminum foil remains bonded to the lip of the container.
You can trust our team of experts to provide you the best solution to your application requirement. Contact us today!
Whatever your project and whatever its scale we are able to apply our experience and range of equipment and materials available to become your partner in the supply of Liner Insertion Machines.
We believe there is no better value medium priced “High End” Induction Sealing Equipment. There are unique features to allow process validation and adjustable width sealing head tunnels are available.
MeRo Induction Systems feature:
- An Air cooled system (Absolutely no need to water cool the induction head).
- Compact construction for easy integration into the filling line.
- High power efficiency thanks to the configuration of the power circuits and the use of IGBT modules.
- Sinusoidal output waveform (Not Square or chopped).
- Constant and Precise Output power due to the configuration of the regulation circuits.
- Easy to use controls that display operating parameters and alarm signals.
- Remote control Start-Stop interface.
- Power variation monitor which can be set by the user to activate an alarm.
- Manufactured in accordance with EN-60204-1 standards, Electromagnetic (EMC) compatibility in accordance with EN-5511 and EN50082-2 standards.
- Motorized height adjustment
- Set-Up Validation providing an Energy absorbed reading- A key advantage over Nearly Every other make
Depending on the range of product and cap/lid/closure shapes, different sealing heads can be supplied.
- Missing Foil Detection with Bottle Eject Mechanism or Signal
- Bottle Accumulation Detection to avoid the situation where bottles are stalled under the active sealing head.
- Pressurized Cabinet version to work in dangerous areas.
- Fieldbus connection to the production process ASI/PROFIBUS/CAM OPEN/DEVICE NET
- Integration of power regulation proportional to the speed of the conveyor via feedback from your existing conveyor’s speed controller. This is another key advantage that MeRo are able to offer over nearly other make.
We believe there is no better value Basic Induction Sealing Equipment on the market today.
The SealerOn™ Basic Induction Machine range is offered to achieve Optimal:
- Machine Value
- Entry Level Induction Sealing
- European Compliance (safe) Equipment
SealerOn™ Basic Induction Sealing Machine Features incorporated into this range include:
- Air Cooled
- Simple Controls
- Semi-Automatic Induction Sealing Option
- Capless Semi-Automatic Induction Sealing Option
- Mid Level Automatic Induction Sealing Option
- Emergency Stop on Mid Level Unit
Because we supply the “big boys” with cap lining material we know our field and we utilize piggy-back productions and stock rolls to be able to service large and small clients alike.
1.0 Valued Clients with Small Scale Cap Liner Requirements:
For the contract Manufacturer, Cosmetics Company, Boutique and Cottage Food Industries, Spices and Small Enterprises, the use of induction liners can give a big boost to their product image and integrity. Finding caps with the liners you need can be difficult or not yet available in the smaller quantities you are dealing with. Loose packed pre-cut liners can be supplied with very short notice; within 2-3 weeks and sometimes much faster. We are at the concluding stages of developing IP that will see lead times fall to well within one week. We use methods that enable cutting tools to be produced for hundreds of dollars rather than thousands of dollars so if your size is unique do not worry.
2.0 Larger Scale requirements and working with Cap manufacturers:
We are introducing tube packed pre-cut liners as an alternative to the more traditional roll form supply of cap lining material.
2.1 Small Scale Cap Liners
Tube packed pre-cut liners are introduced for the small scale and pilot projects as it solves labor considerations and can be combined with cost effective budget liner-insertion-machines.
2.2 Large Scale Cap Lining
In a kind of paradox, the very large scale projects are often best served with pre-cut tube packed liners. The liner inserting equipment is of a much higher sophistication level but the pay-off comes in the better material yield, the elimination of maintaining knifes and dies, the elimination of dust and particle consideration, the more efficient shipping costs for the lining material and the elimination of disposal consideration for the waste generated from cutting from roll form stock. Behind the scene of pre-cut supply, the more savvy pre-cut liner manufacturers also have scavenging and recycling techniques in line with their pre-cut operations to make use of the offcuts generated and this results in a cleaner environmental footprint for this format of cap lining material.
2.3 Innovative Pre-cut Cap Lining Options
We also supply pre-cut liners with innovations that are quite unique and specific to the pre-cut format. Liners with backing having built in pull tabs often require a pre-cut format of cap lining material.