6 Key Principles for Forming, Filling & Sealing Quality Packages on VFFS Machines

Welcome to the latest Kenray Blog looking at the 6 Key Principles of forming, filling & sealing quality packages on VFFS Packaging machines. We are delighted to be joined by our Corporate Partners Greener Corporation.

1. Product Flow

Let’s start at the beginning with Product flow. Problems occur most often when the product is:

 large in relation to bag size
 inconsistent in size or shape
 lightweight
 oddly shaped
 or with rough outer surfaces

Bottlenecks occur when product strings out as it moves from the inlet cone into the narrower confines of the forming tube. In extreme cases individual product “charges” can bridge together. These product flow issues slow down production speeds, create blockages, and cause leakages when product gets trapped in the seal.

On forming tubes with integral cones, the product dose is slightly staggered, so it passes through the bottleneck faster and stays more compact.

2. Forming Set Design

Forming sets should be designed according to your product, package design, machinery, and film specifications. Make sure that this optimal design is accurately and consistently replicated when you order replacement parts or specify formers for multiple machines, lines, or locations.

3. Roller Position

Machine adjustments are also critical for producing quality packages. Misaligned film rollers prevent the film from making full contact with the forming shoulder, causing wrinkles, creases, and package distortions that reduce shelf appeal and cause seal problems.

4. Film Drive

Poor package quality is caused by film drive issues such as belt adjustment and forming tube alignment

5. Former Wear and Damage

Wear or damage to the former lip or shoulder can also distort the package.

6. Sealing

By fine-tuning your forming and filling operations you will improve both package appearance and seal quality.

Leakages
The end seals on packages produced by vertical baggers typically vary in thickness. Most have a lap or a fin seal, and some are designed with gussets. Unintended wrinkles or pleats may, at times, be unavoidable. Leakages, when they occur, often follow channels at the intersections between two and multiple layers of film and at the corners.

Sealing Jaws
Sealing jaws must transfer enough pressure and heat to seal across these channels without crushing, cutting, or distorting the end seal.

• Pressure

In order to create uniform sealing pressure, the serration profile of your sealing jaws should be designed according to your package specifications, machinery, and running conditions.

• Heat
Sealing jaw temperatures are often increased to improve seal quality, but this can create hot spots that overheat and distort the package.

Jaws manufactured from Dura-Therm material provide more responsive, consistent heat transfer across the package to help seal off-channel leakages without overheating the film.

• Wear and Damage
Jaws that are worn, damaged or contaminated with products also create inconsistent pressure and heat transfer that cause seal problems.

To learn more about forming and filling on vertical packaging machines, contact Kenray Forming on +44 (0)1530 400 100. We can also offer remote training and consultancy to help you optimize your packaging operations.

Kenray Forming_sets formadores para envasadoras verticales

For more details on sealing  Jaws, consult the wide variety of Greener “Tech Bites” posted on their P3 Solutions Blog, or contact Greener Corporation.

For further information, please contact Mark Evans on +44 (0) 1530 400 100 or email perform@kenrayglobal.com

 

Kenray Add Horizontal Folding Boxes Capability to its Portfolio of Products

Kenray is delighted to announce that we have added a range of equipment and tooling that has allowed us to launch our design, manufacture, testing and verification of forming solutions for the horizontal packaging market and have invested in new machinery to further enhance this capability.

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This is an exciting new addition to the Kenray portfolio. For the past 18 months, our Engineering Team has been working hard to develop in-house capability to supply leading food manufacturers with forming solutions and a range of applications, including sustainable & compostable film structures that will help ensure packaging is more environmentally friendly. This development will facilitate the use of environmentally friendly film whilst enabling manufacturers to reduce their carbon footprint.

During development, Kenray has become the partner of choice for a number of global manufacturers to design, manufacturer, test & verify solutions for the horizontal folding box market and further investment has been made to widen our capabilities for further testing & verification.

Mark Evans, Commercial Director, and Andrew Dennis, Technical Director said:

“As the packaging sector changes, machinery capabilities need to change in order to offer an efficient solution that is eco-friendly, reduce carbon footprint, and keep machines running at their optimal performance. We have been delighted to be chosen as partner of choice to help design and develop solution’s over the past 18-months and with the future expansion plans in place, this capability can only strengthen our product offering. Exciting times ahead and we look forward to sharing more news over the next few months.

For further information, please contact Mark Evans on +44 (0) 1530 400 100 or email perform@kenrayglobal.com

 

New Testing & Training Centre for Kenray Global

Kenray Forming has continued its expansion plans during the recent lockdown period with the open of its new dedicated testing and training centre at their HQ in Coalville, Leicestershire. Kenray now operates across three sites from their current location focusing on manufacturing, design & R&D, sales and now testing and training.

     

The new Testing & Training Centre has been designed to deliver effective remote training solutions to clients across the globe and technology has been at the heart of the expansion. With travel and site visit restrictions in place at client sites, the new digital training programme in real-time means we can help manufacturers keep forming sets running at optimal and increase productivity.

Andrew Bridgen, MP for North West Leicestershire recently opened KENRAY’s new Testing & Training Centre and took a tour of the premises and met the Kenray Team. During the Open Day, through the use of new technologies, Partners from USA, Italy & India were able to join in the celebrations and tour the new facilities.

Andrew Bridgen MP commented: “Businesses need to innovate in the challenging conditions we are facing right now. Delighted to witness the expansion of Kenray over the years and the future employment opportunities created in the area. With the opening of the new testing & training Centre, I have seen what investment in equipment, training and staff who speak multiple languages can do for a company like Kenray. I am aware it is a major part of UK manufacturing, enhanced by specialist companies like Kenray who have been able to build their international reputation”.

The new testing facility also allows Kenray to continue its programme of research and development into new forming solutions, material options and new processes to ensure its forming sets meet the needs of clients in an ever-changing landscape. Again, Kenray has invested in a range of original equipment to ensure new designs and solutions can be tested fully and adapted where possible. All configurations & types of forming sets can now be tested onsite. We are already working closely with manufacturers to research and develop new material-handling solutions.

This is an exciting development for Kenray which has already allowed for job creation and training solutions have already been delivered across Europe with more opportunities available.

Commercial Director Mark Evans and Technical Director Andrew Dennis added: “Kenray is committed to the design and development of forming sets to meet the needs of our client base and to be able to deliver training solutions across the globe without the need to travel and also to enhance our R&D opportunities by having a test centre, means we are consistently delivering a world-class service. The new building is part of a larger expansion programme for Kenray and whilst world events have meant we need to adapt, we know that the extra support we can offer clients will take our services to the next level.

For further information on Kenray Forming Solutions Testing & Training – visit www.kenrayglobal.com or call the team on +44 (0)1530 400 100 email perform@kenrayglobal.com

 

 

Kenray Forming – Post Covid Support for Clients

Kenray Forming Ltd is located in Coalville, Leicestershire, and over the past week, we have been asked if we are included in the Leicester localised lockdown zone.  We are outside the Leicester area covered by the new lockdown and wanted to take this opportunity to reassure clients the steps we as a company have taken to ensure staff, visitors and client safety:

1. All non-essential personnel have been restricted from the site. Our Sales team are remote working and will continue to do for foreseeable future.

2. Web/video conferencing has been installed across all of our sites to ensure that clients get the information they need. This includes meetings, technical support, and diagnostics.

3. All staff that can work remotely are doing so to ensure our admin and order processing are efficient.

4. All training programmes can and will still go ahead virtually.

5. All staff are following the NHS Guidelines for cleaning and hygiene and contactless deliveries are available where possible.

6. Contactless deliveries where requested are available

Our expert Sales Team is on hand to help and assist with product information and we are committed to supporting our clients, suppliers and the food industry as a whole as much as possible.

Donation to Coalville Community Hospital

The Team at Kenray donated money from their Friday Treats to provide sweet baskets for staff across Coalville Community Hospital.

     

Each Friday, Staff & Directors come together to have a Friday Treat as a way to get our teams together and due to Covid-19 everyone wanted to use the money normally spent to support our local hospital & say thank you to the Staff and Carers working hard on the front line.

Kay Collins – Operations Director said “The team really wanted to make a difference and put a smile on the faces of Nursing and Care Staff at Coalville Community Hospital and what better way to do this than with a number of sweet baskets. We hope they have enjoyed the sweets and thank you from all the Kenray Staff & Directors.

Meet the Kenray India Team

Kenray has made a small but significant step in its evolution by adding a small production team in Asia.

Design and Quality Control will remain under the main UK factory but we can now manufacture closer to our customers in India and Asia making our products more accessible.

For more information about what our new team can do for you please contact Mark Evans on +447956307352 or email markevans@kenrayglobal.com.

Kenray Take on The Three Peaks Challenge in May

A Team from Kenray will be taking on the Three Peaks Challenge in May in aid of local Charity Rainbows.  The team will be taking on Ben Nevis, Scafell Pike and Snowdon.

A practice run up Snowdon has already been completed with the weather changing constantly throughout the climb.

PHOTO-2019-02-14-07-57-41

The Team taking part includes, Ant Guiney, Colin Bosworth & Gary Collins and a fundraising page will be set up to document the training events and to help raise much needed fund for local charity Rainbows.

PHOTO-2019-02-14-07-57-43

Kenray France Welcome Pascal Bruneau to the Technical Sales Team

Kenray is delighted to announce the arrival of Pascal Bruneau who joins the Kenray France team as a Technico-Commercial and will be working closely with Kenray’s Sales Manager, Dan Atkin to support the Kenray team in Péronne with the manufacture and supply in the region for Kenray Forming Sets and accessories.

Pascal brings with him over 18 years expertise and a wealth of experience in the packaging, weighing, dosing and processing industries and will be supporting clients in France and French-speaking areas to assist them with their Forming Sets, Sealing Jaws, Accessories and Training needs.  His technical knowledge is second to none and will be a great asset to the team.

Pascal will also be working closely with Kenray Group Sales Teams in Spain, Italy & Poland to strengthen and enhance the Kenray offering to European clients.

Dan Atkin added: “Pascal has made an impact in the short time he has been with us and clients are already benefiting from his extensive knowledge.  We have plans in place to extend our product offering to our French customers this year and Pascal will be a major part of this growth.

Pascal added “I have been made very welcome at Kenray and when you get the opportunity to meet an incredible team with this energy and dynamics, you can focus on the benefit you can provide to your clients. I am happy to share my experience acquired through different areas, dry products, liquid products, combination of dry and liquids mixing products, using weighing (Linear and Multithreads machines), processing equipment, and mainly for the entire packaging line.

To contact Pascal Brunei

Kenray France
2 Avenue des Australiens, 80200 Péronne, France
+33 3 22 84 13 75

Head Office

Kenray Forming Ltd
Telford Way, Stephenson Industrial Estate, Coalville. Leicestershire, LE67 3HE
+44 (0)1530 400 100

 

UK Sales Team Growth for Kenray Forming Ltd

Kenray Forming Ltd has continued to grow both its UK and International Sales Team with the arrival of Alan Beverley who has joined the UK Technical Sales Team and will be working closely with Commercial Director, Mark Evans and Group Sales Manager, Dan Atkin.

Alan brings with him a wealth of experience with 10 years-experience in the Food industry as well as over 6 years working in the consumables industry.  Alan has already hit the ground running and has been out and about meeting clients and contacts to introduce what he can offer.

Kenray offers clients four decades of experience along with continuous development in R&D and are regarded as the global leader of Forming Sets for VFFS food and pharmaceutical packaging machines.  This high level of experience, combined with the ability to produce large bespoke orders as well as complex one-off projects has seen KENRAY involved in a number of collaborations with blue chip organisations across the globe.

Mark Evans & Dan Atkin added “Our Sales team has gone from strength to strength over recent years and with our exciting plans to grow into new markets and product ranges during 2019, the time was right to enhance our sales team under the leadership of Dan Atkin. Alan will be dedicated on supporting our UK client base, showcasing our latest products and services.

Alan Beverley added – I have been welcomed into the Kenray Team and already enjoying meeting clients and contacts. The plans for the next years are certainly exciting and will help Kenray to be the supplier of choice for all users of forming sets in the UK and overseas.

If there are any of our clients old and new that have any pending or new projects, please do not hesitate in contacting me at alanbeverley@kenrayglobal.com.

 

Continued ISO 9001 Success for Kenray

Kenray are delighted to have received a successful ISO 9001 audit in January and have been re-certified to the new standard.  This new standard will last for 3 years and is a testament to the work Kenray has invested in over the past few years.

The re-certification demonstrates the clear and consistent processes and procedures Kenray has in place to deliver best practice standards.

Commercial Director, Mark Evans said “I am delighted with the continued re-certification of ISO 9001, this is the 6th year that Kenray have been through the audit and reached the required standards level. It is a testament to the efforts of Kay Collins and the Kenray Team ensuring that we continue to perform better both in the UK, Europe and the rest of the world. This is great news for the Firm and continues our passion to be the best!”