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 perform@kenrayglobal.com

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 perform@kenrayglobal.com

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.

Visit – www.kenrayglobal.com or email perform@kenrayglobal.com

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

 

Cost-effective Refurbished TNA Strippers

KENRAY are delighted to confirm that they have developed a robust method to refurbish TNA strippers in a cost-effective, reliable manner. Having developed sophisticated bespoke jigging and production techniques, the team at Kenray can now refurbish TNA strippers to the original, exacting standards.

Kenray confirm that a TNA stripper or bag closer repaired by Kenray, will provide the performance of a new bag closer at a fraction of the cost. The refurbishment process of the TNA stripper sees the parts completely taken apart, cleaned and re-assembled. During the assembly process Kenray use a specialist bespoke jig to ensure all components are accurately aligned and checked, enabling the refurbished bag closer and stripper to operate as new.

Full details are on our solutions page around bags and strippers.

If you need to replace your bag closers and strippers on a regular basis contact Kenray to see how refurbishment could save you money and provide you with greater value.

The Hidden Costs of Average Forming Sets

An important consideration for food manufacturers is the cost of their packaging machinery and forming sets. To cut costs, many packagers will purchase an average forming set, which meets the minimum requirements for safety and hygiene and produces bags suitable for sale. However, the average forming set that was meant to save money up front will often result in additional, hidden costs over time.

There are some common ways in which average forming sets negatively impact the profits of food producers:

 

Small Stops and Reduced Output Speed

Small stops are almost always caused by product blockages, which are caused by a wide range of circumstances. Product with low mass, high surface roughness or wide-ranging variation in unit size commonly can block the former, and integral chutes are required to reduce the possibility of blockages.

kenraytubes-300x290
The design of a straight tube in an average forming set vs a bespoke set’s tube with gradual transition.

However, average forming sets use inlet chutes that do not feature a gradual transition from the chute into the tube, which results in food getting stuck in the machine. When small stops occur, the machine must be turned off and the issue must be corrected by an engineer. Every minute that the machine is off reduces the overall output of your company.

 

Misaligned Tubes

Average forming sets that are fabricated poorly will feature belt flats on the tube that are not an equal distance away from the centreline of the belts. One belt will apply less pressure, which results in uneven tension and it will wear out faster than usual. As such, the belts will have to be replaced more often than they would be with a custom forming set – another hidden cost which will add up over time.

tubemisalignment-300x279

An example of tube misalignment.

 

Problems With Back Seals

Misaligned tubes and shoulders can compromise the quality of the back-seal on the bag, which leads to waste of material. The film may wander off to one side, which will cause the material to ripple while it is being passed through the machine. This can cause the back-seal to expose graphics that are meant to be hidden or hide graphics that are meant to be shown. In some cases, the back seal will come apart. Both food products and packaging material are wasted, which presents a significant dent in the bottom line of food producers.

At KENRAY, we have seen many customers buy average forming sets to save hundreds of pounds in the short term. Unfortunately, over time the equipment presents shortcomings that cost thousands to correct. Our bespoke forming sets prevent these issues from occurring, helping you to increase your production and output.

For more information, view our Forming Set Solutions page or give us a call at +44 (0)1530 400 100. You can also read our full white paper on the Hidden Costs of Average Forming Sets.

Defra to Fund Study on Flexible Packaging

The Department for Environment, Food and Rural Affairs (Defra) has announced its plans to fund a study that will endeavour to improve the recycling and remanufacturing of flexible packaging. The findings could potentially have a significant impact on the packaging of snack products with bespoke forming sets.

The study will take a close look at flexible packaging that contains aluminium, such as pet food containers, toothpaste tubes and snack pouches. Defra estimates that the UK marketplace uses 160 000 metric tons of flexible laminate packaging every year. As such, it is important for food manufacturers and OEMs to become aware of the recycling opportunities for this this type of material.

Several large UK food manufacturers will take part in the study. Nestle UK & Ireland, Coca-Cola Enterprises and Tesco UK will research, develop and test new methods of recovering and treating the materials used in flexible packaging. They will also endeavour to increase the recycling and collection of flexible packaging across England.

Should the trials prove successful, there is the possibility that new viable collection and recycling schemes will be implemented. This could lead to a significant reduction in carbon emissions, ultimately benefitting the environment in more ways than one.

Due to the nature of new materials used in flexible packaging, film control and former accuracy is paramount. Flexible packaging has the potential to pose a challenge to food manufacturers, and it is important to work with packaging experts that can develop custom forming sets to address these issues.

KENRAY has 30 years of experience in helping food manufacturers package their products using a wide range of materials. For more information, visit our Snack Food Formers page or call us at: (0)1530 400 100.

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.