Package Evaluation Training 7 sealingwindow

Introduction Sealing window PE-07/2012-04-01 strip Front Panel Transversal Sealing Introduction Seal in Tetra Pak Packaging System Longitudinal Sealing TS Sealing LS Strip Applicator Sea

Package Evaluation

T i i

Training

Sealing window

PE-07/2012-04-01

1 Introduction

Agenda

2 Transversal Sealing (TS) window

3 Longitudinal Sealing (SA/LS) window

1 I t d ti

1 Introduction

Sealing window

PE-07/2012-04-01

strip

Front Panel Transversal Sealing

Introduction

Seal in Tetra Pak Packaging System

Longitudinal

Sealing

(TS)

Sealing

(LS)

Strip Applicator

Sealing

(SA)

Rear Panel

External Sealing layer

Primer

Internal layer, usually PET

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 SWis the range of energy required to have an acceptable

sealing quality, starting from

a lower limit lower limit= first setting giving a good sealing decreasing the

energy the sealing getsblocked

to

an upper limit upper limit= last setting giving a good sealing increasing the

energy the sealing getsoverheated

Applicable for Transversal sealing (TS), Longitudinal sealing (LS), Strip

Applicator (SA), PullTab (PT),…

►The optimum is defined by the medium value medium valueof the range

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What is a sealing window (SW)?

Example of LS sealing, hot air

Medium setting, 50%

is recommended to use in production

Sealing window is

from 180 ◦ C to

290 ◦ C, medium

value is 235 ◦ C

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

Basic Requirements:

1 Filling Machine perfectly set following MM

2 Test methods

3 Trained personnel

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2 Transversal sealing

i d

window

Sealing window

PE-07/2012-04-01

Transversal seal : Induction heating

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Sealing jaw : Inductor

Pressure jaw : Dollies, Cutting rails, Knife, Spring, Rubber Bushing

Transversal seal evaluation

Tearing

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

►The setting range determined by the test is only valid in the

TPIH 2000 - 2500

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 mount

►Verify the conditions of the cutting rails and inductors, mount

new dollies

►Check the cooling water flow through the inductors (for two

jaws machine)

TS sealing window

►After machine ready in Production state, make a preliminary

Test Execution - General

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, swinging package)

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

TS sealing window

Test Execution – 2 jaws machine

►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 setting

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Lower setting Middle setting 3/4 setting

►At each power setting take out total 20 packages (2

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 li lit ll th li k

the sealing quality among all the link

►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

3 Longitudinal

Sealing window

Sealing window

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Longitudinal seal (LS)

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Longitudinal seal evaluation

Heat distribution zonoscope

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Longitudinal sealing evaluation

Tearing

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

►The setting range determined by the test is only valid in the

Hot air/Induction heating

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

►Check the overlap dimension and overall forming of the

package produced, overlap and forming should be on

package basic condition

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►After machine ready in Production state, make a preliminary

LS sealing window

Test execution

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

►At each setting take out 14 packages for evaluation

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

distribution should >2 mm from strip 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

Sealing window

PE-07/2012-04-01