LinePatrolman™ Accurate Validation and Monitoring of the Induction Sealing Process

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:

  1. 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.
  2. 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).
  3. 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.
Induction Sealing Process Animation
How to Improve Your Induction Sealing Process with the Patrolman™ range

Patrolman Line MasterIf 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 SealMaster Processsealing 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.

SealMaster Validation Tool for Induction Sealing
SealMaster Validation Tool for Induction Sealing

MeRo Induction Sealing 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.

MeRoMeRo Induction Systems feature:

  1. An Air cooled system (Absolutely no need to water cool the induction head).
  2. Compact construction for easy integration into the filling line.
  3. High power efficiency thanks to the configuration of the power circuits and the use of IGBT modules.
  4. Sinusoidal output waveform (Not Square or chopped).
  5. Constant and Precise Output power due to the configuration of the regulation circuits.
  6. Easy to use controls that display operating parameters and alarm signals.
  7. Remote control Start-Stop interface.
  8. Power variation monitor which can be set by the user to activate an alarm.
  9. Manufactured in accordance with EN-60204-1 standards, Electromagnetic (EMC) compatibility in accordance with EN-5511 and EN50082-2 standards.
  10. Motorized height adjustment
  11. 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.

Options include:

  1. Missing Foil Detection with Bottle Eject Mechanism or Signal
  2. Bottle Accumulation Detection to avoid the situation where bottles are stalled under the active sealing head.
  3. Pressurized Cabinet version to work in dangerous areas.
  4. Fieldbus connection to the production process ASI/PROFIBUS/CAM OPEN/DEVICE NET
  5. 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.

SealerOn™ Induction Sealing Machines

 

We believe there is no better value Basic Induction Sealing Equipment on the market today.

Induction Sealing Machine SealerOn 500-Front-View

The SealerOn™ Basic Induction Machine range is offered to achieve Optimal:

  • Machine Value
  • Entry Level Induction Sealing
  • Reliability
  • 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

Induction Sealing Machines

We supply “get-it-right first time” induction sealing equipment that represents a best value proposition for your needs. For less demanding tasks the CE certified SealerOn™ For more demanding tasks we have teamed up with MeRo Italy; European OEM.