Troubleshooting Front Drive Belt Issues – Solutions from Kenray Forming


Mark Evans from Kenray. Today’s short blog is talking a little bit about some of the common problems experienced with front drive belt formers.

Here, you can see a typical former that’s been returned for some refurbishment work.

Typically, you’ll see burn marks on the center of the PTFE strip. Either side of the PTFE strip you’ll see grooves that have been warn by the drive belts.

Here you can see the comparison between the old and the new PTFE strip.

We recommend you change these frequently as the uneven surface will compromise the back seal.

We would also recommend that when you change the PTFE strip, you change the drive belts at the same time. At Kenray,

we’ve developed many variants of the TNA back seal to ensure, proper sealing, particularly with Matt and paper film.

In the example, shown the PTFE is replaced by stainless steel, which also assists in keeping the tube stable.

The insert in the center can be replaced with different materials to seal different films.
So there you have a short video on front-drive belt formers. I hope you found that useful. If you need more information, please either visit our website or give us a call on +44 (0)1530 400 100 or email

Thank you very much.

Troubleshooting Creasing Issues – Solutions from Kenray Forming


So it is a short presentation would like to talk to you a little bit about bag creasing.

One of the reasons for creasing is the age of the shoulder, as the shoulder becomes older, it gets worn by the film as it’s constantly going over the lip. This causes what we call sharks teeth the shark’s teeth that we just described causes the film to rock up as it goes over the lip, this, in turn, causes jagged lines to form down the bag.

Another cause of creasing is when the tube is too close to the shoulder and causes the film to pinch. You can see the consequences of that on the slide shown.
Another cause of creasing can be the role of position which is incorrect and too far back here. You can see that as a consequence of the incorrect role of position. We have creasing on the outside of the bag, which looks like a herringbone
shape and also on the inside of the bag.
So there you can see. Creasing is not only a problem for exterior marks on the bag, but it also breaks the seal inside, and this, in turn, reduces the product shelf life.
So there you have a short video on creasing. I hope you found that useful. If you need more information, please either visit our website or give us a call on +44 (0)1530 400 100 or email

Thank you very much.

Kenray Film Snapping Troubleshooting Solutions


So in this short video, I’d like to talk to you a little bit about film snapping and what causes it?

The film can snap for a number of reasons. Usually, it’s because there’s too much tension.

This could be the result of poor geometry on the shoulder. It could also be because the tube is too close to the shoulder which you can see here. You can see the film is actually peeling rather than ripping.

Sharp edges or the crossover point being too close could also be a key cause of film ripping.

Here you can see the film actually ripped because the gap between the shoulder and the tube is too tight.

So there you have a short video on film snapping. I hope you found that useful. If you need more information, please either visit our website or give us a call on +44 (0)1530 400 100 or email

Thank you very much.

Kenray Onsite Training Facilities


Hello again, Mark Evans from Kenray.

Today, we’re in the training room and I would like to show you some of the facilities we have available for training in our dedicated training facility.

You can either come here in person or we can do it via the Internet on the large screen TV. The TV itself is kitted out with a zoom lens and we can schedule training for any time during the day.

The room itself is kitted out with fixtures, jigging and tooling and we can produce any type of training that you require for more information visit our Training page for more information.

Thank you.

Open Back Seal Solutions from Kenray


Today, I’d like to talk to you a little bit about open back seals and the things that cause them. One of the reasons for the open back seal is that the former is not correctly positioned on the machine as seen on the video above.

You can see that demonstrated. Another reason for the open-back seal could be the tube alignment, in this example, you can see that the tube is offset left to right and in this scenario, the tube is offset front to back.

Another reason for the bag opening up could be the geometry of the shoulder which may be incorrect or the crossover point may be in the wrong position. This is an example of a shoulder where the patterns have been predetermined by forward-engineered models. It will require testing, but this will be minimal.

So here you have a little insight into open back seals to find out more or to let us help you fix some of the problems you may have please either give us a call or visit our website.

Thank you for watching.

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Innovation Leads the Way at Kenray

Kenray has invested in Research and Development in recent years with support from Phill Loxley, our Head of Engineering. This has enabled us to be the industry leader in developing technical solutions for the Packaging Industry. Over recent years, our R&D skills have proved invaluable to leading Blue-Chip clients transitioning to sustainable & compostable film structures that have allowed them to alter packaging configurations and material usage whilst maintaining product outputs on VFFS & HFFS machines.

Phill Loxley, has been instrumental in this development and has been at the forefront of this project and many others. Phill has worked closely with OEM’s & end-users to understand the challenges they are facing.  He has then designed and manufactured a number of innovative solutions along with his team of Engineers that have consistently been recognised by clients. An inventor at heart, the pioneering solutions that we have been able to help companies adopt have made huge impacts such as reduced Nitrogen usage, reduced wastage and improved overall efficiencies.

Andrew Dennis, Technical Director added: “Working closely with Phill, you can see his patience and diligence come through to help clients overcome complex machinery challenges. We are delighted to have been chosen as a partner of choice to help design and develop solution’s over the past few years and with the future expansion plans in place, this capability can only strengthen our product offering.”

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Kenray Video: Stick Pack Forming Set Solutions

Kenray Forming Ltd – Stick Pack Solutions

I’m Mark Evans from Kenray, today we are in the engineering office and I’m going to look at how we produce Stick Pack Formers.

During the first stage, our Engineer will find all the specifications and input them into the model.

The software itself will look for any errors. Once this process is complete the model itself will generate the forward engineered patterns.

Here you can see the typical Stick Pack Former, which has been through this process.

Once this former has been digitally developed, it can be placed together with other formers into the requisite number of lanes.

The next step in the process is to generate the machine tool program using 3D Graphics simulation.


The final part of the process is these images are sent to the machine shop for Machining. Here you can see a stick pack former being milled.

So I hope that gives you some insight into how we prepare and manufacture our stick pack formers.

Thank you for listening. Please contact us on +44 (0)1530 400 100 or email

Kenray Video: Our Engineering Department

Kenray Forming Ltd – Welcome to our Engineering Department

Here we are inside the engineering office.

In total, we have nine Engineers, three of whom are dedicated to research and development.

Here you can see one of the designers who is scanning a customer’s, pattern you will then scan them into the computer and check it against our forward engineered models.

Here you can see one of the designers using a 3D CAD cam. Once the model has been completed it can be sent across to production to be cut on a 3-axis machine.

The Development Department also has a dedicated, highly skilled Fabricator who can turn ideas into products. Here you can see a Kenray redesign of an original part being tested.

Please contact us on +44 (0)1530 400 100 or email

Kenray Video: Our Site 3 Testing Facility

Kenray Forming Ltd – Welcome to our Site 3 Testing Facility


Today we’re looking at our Testing Facilities that we have available here on Site 3.

This Kliklok Woodman Intermittent Machine can be used with either a vacuum or a friction drive facility.  To test TNA and other front drive formers, we have a TNA Robag 3 in our line-up.

Our line equipment LE 400 machine has the ability to test all Doy & Quad formers. All continuous high-speed formers can be verified on this apparatus.

Here we are at the back of the machine and the first thing we’re going to do is to ensure that the reel is correctly positioned on the machine and the film is running true and will be aligned to the bag specification.

So, here we are at the front of the machine all we want to ensure is that the film is running smoothly over the shoulder and touching at every point. will also want to make sure the geometry is correct, and everything is lining up.

Okay so the final point of the process is to check that we’ve got a good bag of the machine First thing to do is to make sure that we got the right bag size, check that we’ve got the correct seal and seal is actually strong enough and then finally check for creases, wrinkles and any twisting.

Please contact us on +44 (0)1530 400 100 or email

Kenray Video: Product Blockage Solutions for VFFS Machines

Kenray Forming Ltd – Product Blockage Solutions for VFFS Machines

What I’d like to do in today’s short blog is to talk to you a little bit about product flow and how we might be able to help you with any product flow issues you might be experiencing

As you can see on the diagram we’ve got potatoes going into a straight tube and as you can see at the top on the right side of the diagram they become stuck in the top of the tube.

So what we’ve been able to do in this particular instance is redesigned the angle of the inlet so that combined with streaming from the weigher. the potatoes flow freely through the tube.

Looking at the diagram on the left, we can see a typical high-speed snack tube, so not only have we altered the inlet angles, but we’ve also cut out the back of the tube to allow the product to fall through the tube freely.

Another way of removing blockages is to use a poker, this is being demonstrated in this clip

Thank you for watching. I hope this and the subsequent videos will give you a little bit more depth into what we actually do. If you need help and support, the Kenray Team are only a phone call away – +44 (0)1530 400 100 or email