Setting an operating window for your induction cap sealer is key to maximizing productivity.

What’s an operating window?
When you set up your induction sealer you should follow an established protocol that identifies the highest and lowest settings on your induction sealer that allow you to acheive an acceptable seal. The range in between is your operating window.

There is a new free webinar and and video demonstrations focusing on setting up an operating window for your induction cap sealer. In addition to step by step instructions on how to set-up an operating window you’ll also find valuable information on learning how to identify a good seal and controlling other variables that can affect your  induction sealing success.

To learn how to improve your induction cap sealer productivity by setting up an operating window follow this link: induction cap sealer operating window webinar.

Induction sealed coffee jar

The packaging sectors in which cap sealers are most utilized include food, pharmaceutical, healthcare, household products, chemical, and other industrial areas.

Package design teams in Europe are using the benefits provided by induction sealers to reduce the pack weight of their containers.  This is primarily achieved by downsizing the material used in the cap and container neck. Since the induction seal prevents leaks and provides evidence of tampering there is no need for a plastic tear band and supporting structure in the container neck.

Food producers in the United Kingdom, France, Germany, Spain and Poland are heavily focused on increasing the shelf life of their products. The hermetic seal created by an induction foil sealer can preserve product freshness and extend shelf life. With the emerging distribution channels being developed  in Europe its clear that those who can provide an extended shelf life will win shelf space on the retail shelves.

Follow the link for more information on induction cap sealers available in Europe.

Induction Sealer seals containers at Bryson Industries

Its no wonder so many of today’s major retailers and distribution channels require packagers to take measures to prevent their packages form leaking. A leaking product can damage an entire pallet of products and create headaches during transportation and in the warehouse. And, if the container leaks when it is in the hands of the consumer,  customer disatisfaction will quickly result.

Induction cap seals offer a simple inexpensive soluton to preventing leaks. An induction sealer hermetically seals containers to ensure the contents stay inside during its journey to the consumer’s home. Recently a manufacturer of cleaning supplies landed a contract with a major television shopping network and quickly recognized a need for induction sealing.

Bryson Industries’ COO  Tommy Lancaster says “All products shipped for the television shopping network or any other customers that use UPS or FedEx are induction sealed for leak prevention with triggers included as separate packaging components. We now test one out of every 60 induction seals and find less than .001 percent to not be sealed properly. And usually it’s through no fault of the induction sealer.  We no longer get damage claims, so we’re able to keep our ‘on-time, every-time’ promise to our customers.”

Find out more about Bryson and their use of induction sealers to prevent leaks.

In addition to the energy savings obtained by the eliminating water recirculators, the new induction cap sealers have  reduced downtime, maintenance and the defective products. In fact, Catania-Spagna reports that they have saved thousands of dollars a year by upgrading their equipment.

“The water recirculator had to be flushed on a regular basis. We also struggled with rust and corrosion from the water recirulator. Now, the down time is practically non-existent,” says Sampson.

 The induction sealing machines seal high density polypropylene (HDPE) containers ranging from 3 liters to 2.5 gallons. The cap sealers from Enercon feature an All-in-One sealing head which seals caps ranging from 20-120mm.

Catania-Spagna’s green initiaitve also  includes the installation of energy efficient air compressors, variable-frequency drive pumps and motors, a new lighting system and an in-house recycling program. In the proces sof being green Catania-Spagna has saved upwards of $100,000 a year on energy costs.

Catania-Spagna efforts were the subject of a recent article in Packaging Digest magazine and more information about the induction sealers used to seal their cooking oil products can be found be following the underlined links.

“Schuelke explains how Enercon examined every aspect of its current super seal product line in order to define customer objectives, the primary two being ease of use and increases in productivity and throughput. Schuelke points out that Enercon’s new Quick Start Guides reduce the time from out-of-the-box to operation. Aiding this objective are universal input voltage capability, container centering beacon, quick connect inspection and single interface for inspection and rejection. These features slash setup time from hours to minutes, says Schuelke. Also aiding ease of use are intuitive touch screens, operator lockout or password protection, availability of eight languages and recipe management, which minimizes changeover time.

 Ease of use greatly enhances productivity, another user objective for induction sealing equipment. The efficient sealing head design optimizes energy use, explains Schuelke, by directing the sealing energy to the liner.

Performance in the plant setting is also improved by harnessing data from the induction sealer. Packagers can utilize internal data to identify trends in machine operation and leverage that information into increased efficiency. Enercon’s induction sealers provide diagnostics–which Schuelke describes as invaluable–and fault logs.”

To learn about the highlights regarding induction foil liners please read Mary Ann’s report based on BJ Radek’s (Selig Sealing Products) presentation or check out the entire Future of Induction Sealing Webinar by following the link.

Andrew Lerch, production manager-packaging for PURE BioScience says, “The sealer installation was quick and painless. We took it out of the box, leveled it, and it was running immediately. Since installing the Super Seal Touch, we have increased production, decreased our downtime, and are more confident about the integrity of our packaging than ever. Induction sealing speeds now are approximately 40 bottles per minute. On a scale of one to ten, the next time PURE BioScience purchases an induction sealer, the likelihood of it being a Super Seal is a ten.”

Touchscreen operation, air-cooling, and integrated cap and foil inspection were critical in improving the company’s packaging of ready-to-use disinfectants in HDPE bottles. The induction seal features a polyfoam lining which helps ensure a 2 year shelf life.

Additonal information on this application can be found by clicking on the following link: Cap Sealer Prevents Leaks on HDPE Containers

Portions of this induction sealing article is Copyright 2010 Summit Publishing Co. All rights reserved. PACKAGING WORLD® Magazine is reprinted by permission of Summit Publishing Co. PACKAGING WORLD is a registered trademark of Summit Publishing Co.

Induction sealers create hermetic seals that prevent leaks, preserve freshness and provide tamper-evidence. Companies in the pharmaceutical, food, beverage, petroleum industries are creating product differentiation and consumer preference for their brands by ensuring these features are delivered to Indian households.

That’s why packagers across India from Bangalore, Chennai, Kochi, Hosur, Kolkata, Mumbai, New Delhi, and Hyderabad are incorporating induction sealing as part of their packaging strategy.  As a non-contact packaging process induction cap sealers are very easy to integrate into any packaging line. New high performance air cooled systems are making it easier than ever for start-up operations and high speed packagers to add value to their products with an induction seal.

Follow this link to see some of the companies who currently induction seal in India.

Mary Ann reported on three key topics:

“Sustainability initiatives encourage the ongoing move from glass packaging to biopolymers, such as polyethylene terephthalate (PET) and polypropylene (PP), says Radek. While hot fill, pasteurization, retort and aseptic processes present some induction sealing challenges, companies are successfully integrating induction sealing as part of their conversions. Recent examples include Kraft Mayo and Kraft Maxwell House instant coffee, both of which utilize foil innerseals.

 The need to thwart counterfeiting, especially in the pharmaceutical market, is an urgent undertaking, with induction seals playing a significant role, says Radek. Solutions include etched or engraved foil, color-shifting inks, micro-printing, printed or electronic (RFID) codes, custom colors and tagents (inks with DNA added).

Radek says the two aspects affecting induction sealing worldwide are sustainability and new two-piece waxless innerseals.  Lightweighting of containers –and also of the liners themselves – is a trend.  Selig’s new Lift’n’Peel™ R liner has the capability to be separated and recycled in the PET bottle recycling process in Europe and has the potential to be recycled globally.  Radek describes the waxless two-piece innerseal as an exciting development since it is robust, yet fragile enough to separate when the closure is removed.”

The webinar was moderated by Packaging Hall of Famer Ben Miyares and Ryan Scheulke of Enercon Industries Corporation also presented.

Highlights include increased sealing power, a new fully integrated cap inspection system, touch screen operation and network connectivity. The induction cap sealer is ideal for high performance packaging lines, such as found in the pharmaceutical industry. More information on the Super Seal™ Touch is available on Enercon’s website.

Induction cap sealers ensure cosmetic products will not leak.

Induction cap sealers solve leaking cap problems for both fortune 500 companies and small packaging operations.  In the consumer’s mind visual packaging imperfections devalue their opinion of product quality.  In a retail store a leaking package will be left on the shelf.  If the package leaks on the way home a customer may be lost forever.

Jennifer Hardaway, founder of KLEAN Bath and Body, doesn’t sell her products through retails outlets, but she did need to find a solution to prevent her body scrubs and lotions from leaking when they arrived at her customer’s doorstep.

An on-line search for packaging solutions led her to induction cap sealing. She was pleased to discover that induction cap sealers are an economical investment. For her production volume, a table-top induction cap sealer ensured that her cosmetics would be hermetically sealed until they arrived safely at her customers’ homes.

The model she selected offered portability which is a nice feature to have for a growing business. With the packaging security of an induction sealer her business is thriving. As Jennifer says regarding her investment in an induction cap sealer, “Peace of mind is worth every penny.”