End seal leakage is one of the most common and frustrating challenges in packaging. It compromises product freshness, increases waste, and can cause significant downtime. Fortunately, with a proactive approach, this issue can be effectively managed. From equipment adjustments to material upgrades, there are many ways to ensure your packaging maintains its integrity.
Here are six proven solutions to minimise end seal leakage.
1. Schedule Regular Maintenance
Misaligned sealing jaws are a leading cause of end seal leakage. Over time, wear and tear can disrupt the alignment, resulting in inconsistent seals. Regular maintenance helps identify and resolve these issues before they escalate.
During inspections, focus on areas like jaw alignment, wear on components, and smooth operation of the sealing mechanism. Addressing minor issues early can save both time and money in the long run.
2. Optimise Sealing Parameters
Temperature, pressure, and dwell time are the three key parameters that determine seal quality. If any of these factors are off, the integrity of the seal can be compromised.
Ensure that the sealing temperature matches the requirements of your packaging material. Too little heat won’t bond the seal, while too much can degrade the material. Similarly, adequate and even pressure across the sealing area is essential for a reliable bond. Take the time to test and fine-tune these settings for each material and production run.
3. Check Jaw Profiles and Serration Patterns
The design of the sealing jaws, including their profile and serration pattern, plays a significant role in forming a strong seal. A poorly matched or worn profile can lead to weak seals or gaps.
Upgrading to a serration pattern optimised for your material and machine can improve seal consistency and reduce leakage. Regularly reviewing the condition of the sealing jaws ensures they maintain their effectiveness over time.
4. Use Quality Packaging Materials
Low-quality or incompatible materials can make it difficult to achieve a secure seal. Inconsistent thickness, poor heat resistance, or substandard film properties are common culprits behind seal failure.
Investing in high-quality materials specifically designed for your sealing equipment can significantly reduce leakage. Testing different materials under production conditions can help identify the best option for your needs.
5. Maintain Proper Film Alignment and Tension
Film misalignment or improper tension can cause wrinkles and uneven seals, leading to leaks. Ensuring that the film feeds smoothly through the machine is critical to achieving consistent results.
Regularly inspect rollers, guides, and tension settings to confirm that everything is aligned and functioning correctly. Training operators to recognise and address alignment issues quickly can also reduce the risk of seal problems.
6. Incorporate Regular Seal Testing
Even with well-maintained equipment and high-quality materials, periodic testing of seal integrity is essential. Tools like burst testers and peel testers can provide valuable data on the strength and reliability of your seals.
Incorporating these tests into your quality control process helps catch potential issues early, allowing for adjustments before defective products reach the market. Testing also ensures that your seals meet industry and customer standards for durability and freshness.
Partnering for Sealing Success
End seal leakage is a common challenge, but it can be effectively managed with the right combination of maintenance, adjustments, and expertise. From ensuring proper alignment and optimising sealing parameters to recommending advanced materials and designs, Kenray provides the tools and expertise needed to address these challenges head-on.
Our team can help you implement these solutions, perform detailed line assessments, and ensure your packaging operations run seamlessly. If you’re ready to minimise leaks and maximise efficiency, contact us today to discuss how we can support your packaging success.
