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Posted on by Claire Taylor

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 [email protected]

 

Kenray Forming, Forming Sets, VFFS, Packaging
Posted on by Claire Taylor

Packaging: 20 Years of Change

Packaging began simply as a way to protect food, keeping it fresh and clean until it was eaten. But it was not long before it acquired a range of other purposes such as branding, sales, and usability.

With all these areas invested in packaging, it is no surprise that companies are constantly growing and developing the ways they package their food. As a result, there have been huge changes in the industry over the past 20 years.

 

Going Green

Related to wastage, environmental concerns have also had a huge impact on the packaging industry. As well as being a factor driving the reduction of material wastage, environmental issues have affected the type of material used. Far greater quantities of food now use packaging which is recyclable or has already been recycled. These factors have also left their mark in the field of design and labelling. Most food packaging now includes advice on how the materials can be disposed of in the most environmentally-friendly way and whether the packaging is recycled. Brands that wish to show their environmental responsibility to their customers may also mention the fact their packaging is recycled clearly and visibly on the label.

 

Calorie Counting

Perhaps one of the most significant and noticeable changes in packaging over the last 20 years has been the inclusion of nutritional information. Concerns over public health and new legislation have led the inclusion of this data to be near-universally applied to food packaging. It has also become part of the selling process. Healthier foods, or brands that wish to convey a helpful and health-conscious image, put essential facts about a product’s nutrition in prominent places on the front of the pack.

 

Standing Out From The Crowd

Companies are keen to make their packaging stand out on the shelf, as well as ensuring it looks modern and impresses the customer. As a result, the field of packaging design has seen huge advancements.

New technologies have allowed labels to become more colourful and complex. A range of new shapes have also been developed, either for practical reasons or to look modern and unique. A range of forming shoulders are now widely available to help produce shapes that were unheard of 20 or even 10 years ago.

 

Reducing Material Wastage

Through the later part of the twentieth century, a number of studies in different countries were coming up with disturbing wastage figures. Not only were packaging materials being wasted in the manufacturing process, but inadequate packaging was leading to the wastage of large percentages of products. In Russia, for example, more than half of fresh fruit and up to 70% of potatoes were wasted for this reason. More reliable manufacturing processes, through the use of modern formers and more advanced equipment, have slashed these figures.

Kenray Forming, Forming Sets, VFFS, Packaging
Posted on by Claire Taylor

Two Decades of Change in the Packaging Industry

Since its humble beginnings as a simple means to protect food and keep it fresh, packaging has developed and changed to play a much more important role in many ways. For example, it now offers a whole host of other purposes including branding and usability instructions, and exciting designs to increase sales.

Companies tirelessly review and renew their packaging, investing large amounts of capital into the process and developing the way that products are packaged. This has seen large scale change in the packaging industry over the last couple of decades.

 

Packaging Design

Perhaps one of the most important considerations of modern day packaging is the design. It is imperative for companies to be able to provide a product that is packaged in a well designed way that is impressive to the customer. This necessity has facilitated the advancement of packaging technologies.

In addition to allowing more colourful and complex designs to become more easily viable, packaging technological advances have also allowed for unique and modern shapes to be easily made. Forming shoulders are able to assist with creating intriguingly shaped packaging that was simply unavailable from 10 to 20 years ago.

 

Wastage

Towards the end of the 20th century, studies and surveys across the globe found troubling and concerning wastage figures that saw packaging materials being wasted during the manufacturing stage, and also that poor quality packaging was leading to product wastage. This was of particular concern in Russia, where 70% of potatoes and over half of all fresh fruit was being wasted because of this reason. Modern manufacturing processes including the use of advanced equipment such as formers and forming tubes has resulted in even less wastage.

 

Environmental Considerations

Closely linked to wastage, the packaging industry has also been affected by environmental concerns. Not only does this fuel the desire to keep wastage at a minimum, it also has led to further considerations such as materials used. As a result, many foods now come in recyclable packaging, or packaging which is made from already recycled materials. This in turn has had an effect on packaging design, as most products now come with clear instructions on how the materials can be disposed of or recycled in the most ethical and environmentally friendly manner.

For some brands, their dedication to the environment is a key part of their sales pitch, and so the fact that they use recycled and recyclable materials in their packaging may become an integral part of its design.

 

Health and Nutrition Information

Another key change to packaging over the past 20 years has been the nutritional information that is present on food products. Public health concerns and new legal requirements have led to the inclusion of such information on packaging. As a result, not only does this conform to legislation, it again also becomes part of a brand’s market placement; many companies focus their strategy on promoting their message of selling healthy products, and so may include this information in a prominent place on the packaging. Health conscious buyers and customers are also attracted to this, so many companies highlight their health and nutrition information to attract more sales.

Kenray Forming, Forming Sets, VFFS, Packaging
Posted on by Claire Taylor

Colegate Calls for Recyclable Packaging

Colegate-Palmolive has recently announced new commitments to recyclable packaging. In particular, the company has spoken out against the increasing adoption of non-recyclable flexible packaging.

More and more products are now being sold in flexible, non-recyclable plastic packets. Raisins were once commonly packaged in little cardboard boxes, but now they use flexible packaging. Likewise, drinks traditionally come in bottles, which are usually made of glass or PET, or else in aluminium cans. All of these can be economically recycled. But now, some products such as Capri Sun, which is immensely popular with children around the world, come in flexible packaging that is difficult or impossible to recycle. All in all, 2012 saw sales of products in such flexible packaging reach levels of over US$26 billion in the US alone.

So what has made companies invest in the formers, forming tubes and other packaging machine accessories necessary to completely change their packaging to a non-recyclable option?

Cost, of course, could be one factor. Flexible packaging is often cheaper to produce, offsetting that initial investment in new forming sets and packaging machine accessories. Nonetheless, it is surprising in these days of environmental awareness and increasing corporate responsibility to see such a large shift away from recyclable materials.

However, some companies may have made the change with genuinely good eco-intentions. In the short term, manufacturing this packaging generates lower levels of emissions and uses less material. However, while this makes sense in the short-term, the fact that these products cannot be easily recycled offsets the initial advantages. There are few disposal options available except for incineration or landfill, and then the manufacturing process for new packaging begins again from scratch.

Indeed, misguided views on the eco credentials of flexible packaging are making their way to the very heart of the packaging industry. In a recent interview, green design advisor and sustainability architect William McDonough said “I see packaging awards being given to these pouches as more efficient containers of, say, a cereal.” He then pointed out that this product, traditionally placed in an easily-recycled cardboard box, is now “wrapped in seven plastics with undefined inks and metallized polymers. It doesn’t have a recycling symbol on it because you could never recycle it… And yet it’s being put forward as a more efficient package.”

Now Colegate have taken their stance against this non-recyclable packaging, they seem to mean business. For three out of four product categories in the company’s portfolio, they have committed to making all packaging recyclable by 2020. For their remaining product category, oral care, they are working on development of a recyclable toothpaste tube, or a new kind of recyclable packaging to serve the same purpose, so that the remaining products can follow suit.

Kenray Forming, Forming Sets, VFFS, Packaging
Posted on by Claire Taylor

The Debate over Recyclable Packaging

recyclelogo1

More and more companies are making the shift towards packaging their products with recyclable materials. While it is certainly a more environmentally-responsible approach, many companies continue to use non-recyclable packaging. So, why haven’t all companies made the switch yet?

Even though we are seeing plenty of companies using forming sets to package products in recyclable materials, there has also been an increase in the number of products that are being packaged in flexible, non-recyclable materials. A prime example of this is Capri Sun, the popular kids’ drink packaged in materials that are virtually impossible to recycle.

Cost is the major factor behind the use of flexible packaging, since it is often cheaper to produce due to the materials required. There are also some short-term ecological benefits, as this type of packaging generates fewer emissions and uses less material overall.

However, on a long-term scale, recyclable packaging is more beneficial. Flexible, non-recyclable packaging may be cheaper for manufacturers to produce and more convenient for consumers to use, but it is a major drawback that the material cannot be recycled. This type of packaging can only be disposed of in an incinerator or landfill.

One company that has taken up the cause is Colgate, as the company has taken a stand against non-recyclable packaging. For three of four of their product categories, the company will make all of its packaging recyclable by the year 2020. Oral care is the remaining category, and Colgate aims to develop a new recyclable toothpaste tube in coming years.

When making the switch to recyclable materials, brands may require different forming sets to ensure the efficiency of the packaging process. At Kenray, we work with our customers to understand the different issues relevant to your food processing needs, such as recyclable packaging, product flow, bag quality and sealing issues – as well as temperature, material and volume requirements. As such, we can advise you on the ideal type of forming set or even build bespoke formers to suit your packaging needs.

KENRAY can help you find the ideal forming set for your recyclable packaging. For more information, visit our Forming Sets page or call us at: +44 (0)1530 400 100.

Kenray Forming, Forming Sets, VFFS, Packaging
Posted on by Claire Taylor

Packaging trends 2014: Predictions

With 2014 still in its infancy, now is the right time to consider what the year ahead holds for the packaging industry. Expert predictions have indicated some interesting potential developments, so it’s important to take note of these ideas and plan accordingly, in order to ensure that you are a leader in your industry. Taking advantage of advanced predictions in terms of machinery, health and safety, and the environment are just some of the considerations when studying the upcoming trends over the next 12 months.

 

Environmental considerations

More and more people are tuning in to the importance of environmentally friendly manufacturing processes and the need for materials to be recyclable and sustainable. For a growing number of people, sustainability is cited as an integral factor when they choose which products to buy or use. This rise in awareness and interest in sustainability is reflected across all business sectors, and it is therefore becoming increasingly important for packaging manufacturers to focus on environmental issues. In terms of packaging, one way to become more environmentally friendly is to reduce packaging sizes to as small as possible. As a result, formers and machinery like forming collars and similar pieces of packaging machinery need to be able to manage and cope with reductions on package sizes. Forming tubes and shoulders can, when used correctly, also reduce wastage and aid sustainability.

 

Health and safety

Concerns over the safety of products continues to loom large within society, and it is therefore important for packaging manufacturers to consider this. In particular, food packaging must be able to provide safe and healthy consumption. As awareness rises regarding diet, people are taking more and more interest in nutritional information. The packaging industry has recognised this by incorporating key nutritional details on packaging. Meanwhile, demand grows for smaller portion sizes, and many packaging companies are now looking to include such products, for example 100 calorie snack packs. Reducing pack sizes again calls for the correct packaging machine accessories, machinery and equipment such as forming tubes and forming collars.

 

Globalisation

As brands grow, they not only look for localised growth, but in maintaining a global presence with a recognisable character. As a result, design is as important as ever in terms of packaging. While slight changes to packaging design may continue to occur to match localised tastes and trends, consistency is becoming more and more key to keep up with the demand for instantly recognisable brands. Creating packaging that includes colour, shape, and logos (along with layout) can be important to establishing and developing a recognisable brand.

 

Retail relationships

The demand for packaging from the retail sector continues to grow. Many retailers are now looking to provide own brand alternatives to established brands, and as a result require professional and engaging packaging. Manufacturers therefore have an onus upon them to justify the premium prices that they command. In order to cope with the demand of high quality packaging from retail groups, packaging machine accessories and machinery must be correct. Forming tubes and forming collars are a vital step in offering structural improvements to retailers through packaging.

Kenray Forming, Forming Sets, VFFS, Packaging
Posted on by Claire Taylor

Decades of Development in the Packaging Industry

With over 30 years of experience in the food packaging industry, KENRAY has seen many changes and developments to the way that food is packaged. While it originally started out as a way to protect food and keep it fresh, packaging has developed to serve a number of other purposes, including branding, environmental-sustainability and reducing food or material wastage.

 

Food Packaging Design

One of the most crucial aspects of food packaging today is design. Companies aim to ensure that their packaging is designed in a way that captivates and impresses customers. As such, there has been an increased need for advancement in food packaging technology.

If manufacturers want to sell their products in interesting ways, they require vibrant colours and designs. New technological advancements make colourful packaging more viable and allow for unique shapes to be made. Forming sets and shoulders help to create this type of packaging, which simply would not have been seen on grocery store shelves twenty years ago.

 

Wastage

In the past, studies showed that an alarming amount of food packaging material was being wasted both during and after the manufacturing process. Today, innovative sealing jaws help reduce leakage, which keeps food fresh and prevents wastage. They also run on a low temperature to save energy and production costs.

To further reduce waste, more and more refrigerated products are being sold with re-sealable packaging. Subdivided packages also help in this respect, as they allow you to use some of the product now and save the rest for later without opening the package.

 

Environmental Concerns

In the packaging industry, we are also seeing a shift towards sustainability. Manufacturers want to keep food and material wastage to a minimum, so many foods are packaged in materials that have been recycled or can be recycled in the future.

In turn, this has had an effect on the physical design of packaging, as products are printed with clear instructions about disposing the material in environmentally-responsible manner. Many brands even use their sustainable packaging as a selling point.

 

Nutritional Information

Over the course of the past few decades, we have also seen the addition of nutritional information to food packaging. New health regulations have led manufacturers to include information about calories, protein, fat, sugars and carbohydrates on their products. This has also become a part of the marketing strategy for many companies, as their packaging helps them promote their commitment to providing healthy foods to customers.

For more information on how KENRAY’s innovative technology can benefit your products, visit our Packaging Solutions page or contact us.

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Posted on by Claire Taylor

Choose the right forming set to reduce packaging costs

One of the major considerations faced by packaging businesses is the selection of an appropriate forming set. Ensuring that you choose the correct forming set is of paramount importance to the running costs of your business. It’s not just the initial price that defines the cost-effectiveness; after all, it becomes an essential part of the packaging process, and using appropriate forming tubes and forming sets that are of high quality can ensure your business isn’t wasting money.
Less material wastage

Nobody likes to lose money through production faults, so using the correct forming shoulders is vital. This ensures that packaging materials are used more efficiently, and as a result means that fewer materials are wasted. Less waste means less time and money is lost to a final product that is unusable, and also means that precious time is not spent producing a flawed product.
Fewer blockages

Another common drain on time resources in the packaging industry is caused by blockages in forming tubes and collars. Many product types are prone to these blockages, which has a negative effect by slowing the production process and rendering the machine useless until the blockage is cleared.

Using higher quality, purpose-built forming tubes, which offer intricate designs to reduce the severity and frequency of blockages, can be a beneficial way to minimise this kind of setback. These tubes will be designed with wider inlets to reduce the chances of a blockage, along with unique shaping of the tube. This helps by allowing the machine to do its job; producing the profitable products.

Despite this, it is not always necessary to buy purpose-built forming tubes that prevent blockages. While some are prone to blockage, there are some product types that do not commonly suffer such fate.
Optional features

High quality forming sets are often tailored to suit the particular needs of a company, with many suppliers offering a host of optional features to increase efficiency and functionality. This can allow your company to increase the volume of output. Such features are intended to provide a balance between cost and the running of the business, which improves the optimum outlay level and maximises business profits.
Longer lifespan

It is an inevitable circumstance that forming collars and tubes will fall victim to wear and tear as time passes, and will eventually need replacing. Using higher quality forming sets, which are much more tough and durable, means that they will need to be replaced much less often than cheaper and more flimsy alternatives. In the long run, this means that although the initial outlay may be higher, money will be saved by the infrequency at which the tubes need to be replaced.

In summary, the selection of the right forming set is a vital factor in the running cost of a packaging business. While higher quality sets may be more expensive initially, their lower repair and maintenance outlay over time makes them much more cost-effective than basic sets. Additionally, a high quality forming set and collars allow your business to maximise productivity and consequently increase profits.