Induction Sealing Machine: The Ultimate Guide
Do you know induction sealing offers a reliable packaging solution?
And if you want to try this technology, you need an induction sealing machine.
Today’s guide walks you through all the fundamental aspects of induction sealing machine – from basic definition, technical specification, history to working principle, among others.
Let’s get started.
- What’s Induction Sealing Machine?
- History of Induction Sealing Technology
- Benefits of Induction Sealing Technology
- Types of Induction Sealing Machines
- Main Components of Induction Sealing Machine
- Induction Sealing Machine Sealing Principle
- Common Induction Sealing Problems and Solutions
- Induction Sealing vs. other Types of Sealing
- Other Support Equipment in Induction Sealing Process
- How to Select a Suitable Induction Sealing Machine
- How to Install Induction Sealing Machine
- Uses of Induction Sealing Machine
What’s Induction Sealing Machine?
Induction sealing machine – Image source: CLEVELAND
Induction sealing machine generally applies the induction heating technique to seal non-metallic containers, i.e. glass and plastic containers.
The induction heating technique involved in this case has various applications, but mostly it’s utilized in the cap sealing.
So, for cap sealing, it involves a non-contact mechanism of applying heat to the inner seal (usually aluminum foil since it’s an electric conductor) of the cap to firmly seal the plastic or glass bottle.
What primarily happens here is that during induction heating, the induction unit emits a strong electromagnetic field.
It blasts the cap and in return, the liner (aluminum) generates heat due to the eddy currents involved.
Eddy current in induction sealing – Image source: Penglai China
However, you need to know that inner seals are only advisable to use with containers of specific materials such as:
- Polyvinyl chloride
- Polythene, and other related thermoplastics.
Regardless of that, you have to take note that the induction sealer also does capless sealing and not restrictively cap sealing.
That’s why you’ll notice some packages sealed using only aluminum foil but capless.
Though, in either case, the procedure is purely non-contact and doesn’t make use of direct heat transfer.
We shall have a close analysis of the working principle later in the guide.
Even so, sealing occur after the complete filling and capping of the containers.
History of Induction Sealing Technology
Scientists believe that the induction sealing concept tracks back in 1957 when a scientist Jack Palmer conceived and proved it.
He, however, was focusing on coming up with a viable solution for the ever occurring problem of liquid leakage from polyethylene-based bottles during shipping.
Indeed his success was recognized and appreciated by U.S Patent in 1960 when it became an outright public idea.
Later on, in 1960, the whole globe conceptualized the idea.
After that, a series of inventions arose, including the introduction of high tech induction sealers.
And with such concurring improvement in sealers’ systems, in 2004, the manufacturers achieved a milestone.
Thanks to the actualization and introduction of a 6 kW machine.
Benefits of Induction Sealing Technology
Induction sealing machine – Image source: Wikimedia
We can attribute the reasons why most companies prefer using induction technology to the various advantages associated with the whole procedure.
The following are some of the fundamental reasons.
· Leak Prevention
Without a proper seal, there would be enormous spillage of liquid or fluid contents from containers, especially during transit.
However, with induction sealing, it’s easier to achieve a leak-proof container for shipping various goods, including toxic ones.
· Tamper Evidence
The FDA regulations obligate the companies to follow suit on the tamper-resistant packaging.
And indeed, the heat induction process avails tamper-resistant seals to the containers in comparison to the adhesive based seals.
· Preservation of Freshness
Undoubtedly, the freshness of content is a guarantee for the consumption of a product.
With the induction sealing technique, no external pollutant may seep through to contaminate the containers’ content.
Thus no chances of compromising freshness.
· Preservation of Pilferage
Many a time, you’ll get containers which have got liners either film or foils.
These induction sealed containers makes it difficult for unnecessary interference of the products.
More so, pharmaceutical companies include the inner seal on their product bottles.
· Improves the Durability of Products
Proper induction sealed containers have no chances of contamination by any external pollutants.
It, therefore, enables the preservation of quality and thereby eliminating any possible product compromise, eventually lengthening the product’s shelf life.
· Enhances Customer Satisfaction
Induction cap sealing of containers helps create a general notion of credibility check of the contents; in this way, the consumers get assured of the overall product quality.
Consequently, complete satisfaction arises.
· High speed of Production
Induction sealing highly utilizes high rapid electromagnetic induction emitted from an induction sealing machine.
Such high velocity and frequency thereby translates into faster sealing and hence fast production.
· Stamps Secure Seals
The kind of seals achieved from induction sealing technology is highly secure and protected.
So, that kind of security makes it difficult for some degree of damage or interference.
Types of Induction Sealing Machines
Since the full actualization of the induction sealing technology, many manufacturers specialize in the production of these systems.
Therefore, with such trends and numerous assemblers, there exits several designs and types of induction sealers.
Even so, you shouldn’t find it hard to pick the most efficient or sophisticated one that’s suitable for capping in various ways.
For that reason, we shall analyze the different existing induction sealers. Have a look.
1. Continuous Induction Sealing Machine
The continuous induction sealer type is very suitable for conducting an uninterrupted capping operation of non-metallic bottlenecks containers.
Due to that kind of non-stop operation, the sealer is compatible with dealing in large scale input and output.
Continuous induction sealing machine – Image source: Wikimedia
Advantages of continuous induction sealing machine include:
- Suitable for handling a vast bulk of sealing containers
- Guarantee large scale output
- Faster capping and sealing
- Constant operation
- Wide range of applications in several industries (including pharmaceutical, chemical, food and cosmetic)
- Available in various designs for sealing a wide range of bottleneck diameter
On the other side of the spectrum, the sealer suffers from a few limitations such as; not applicable with metallic bottlenecks or non-threaded caps.
The following are the distinct parts of the equipment: speed conveyors, induction head, air cooler/ regulator, wheels, control panel.
Identifying a continuous induction sealing machine is simple and straightforward.
All you have to do is to confirm some of the following features:
- It applies the electromagnetic induction principle
- Achieves a higher level of production
- Adjustable and motor fitted induction head
- Easy variable speed conveyors
- Production of instant heat that melts the aluminum foil.
- The equipment conforms to quality compliance such as GMP standard, FDA regulation conformity.
- Stainless steel material structure.
- Seals and caps a range of bottlenecks diameters and accommodate a wide range of container heights.
- It employs a printing embodiment on the caps with product details, brand or even factory logo, etc.
- The sealer consumes little power as low as 2.0 KW.
2. Manual Induction Sealer Machine
The manual electromagnetic induction sealer is almost an entirely manually driven piece of equipment.
It is suitable for customers or users who deal with small scale input and likewise need a low output.
Manual induction sealer machine – Image source: Wikimedia
Even though it’s a manual type it has several benefits including:
- Relatively low initial buying price
- Sealing time ranging between 0.2 to 2 seconds depending on both the bottle material as well as machine type
- Moderate consumption of power
- Suitable for small forgery
- Ideal for serving numerous different industries ( Pharmaceuticals, food, chemical, and oil)
- Considerable production speed, and output some have got an approximate production of up to 360 containers every hour
Apart from that, the machine suffers from the following disadvantages:
- Unsuitable with extensive manufacturing
- Seals an only limited range of bottle sizes
- Doesn’t seal or cap metallic bottlenecks
The main parts include cable, digital/ manual up/ down timer, control panel, heating plate (sealing surface).
Some of the main parts of the manual induction sealer machine include the following:
- Sizeable heating plate/ surface which has an adjustable height for sealing a wide variety of plastic bottles.
- Occupies very little space, they’re small in dimensions thus enabling the user quickly and optionally mount it onto a tabletop or counter.
- Small weight, some weigh as low as 6kg.
- Portable due to lightweight.
- Some have got a backup power storage/ battery. Therefore, it isn’t entirely dependent on electricity such that it operates even during a power outage.
- Requires customizable outer material, either plastic, stainless steel.
- Equipment consumes little power and low voltage.
3. Capless Induction Sealing Machine
Capless induction seals – Image source: Relco
Unlike the conventional induction sealing technique, the capless induction sealing means provides an airtight seal straight into the containers.
Or any other components without necessarily requiring the necessary need of a cap and a screw thread.
Therefore, means that the machine punches the seal material directly onto the container.
However, this process is a bit complicated in comparison to the usual cap induction sealing.
The technique initially involves a mode of delivery of the seal to the containers and subsequent application of pressure to the seal.
Capless induction sealer
The benefits attributed to the capless sealing technology are numerous.
The following are the key advantages.
- It enables complete visual inspection of the seals.
- Makes it easier to personalize and take charge of the sealing procedure.
- Gives more room for adequate cooling of the seal, especially with containers that have high-temperature contents.
- The seal adheres properly to the container, especially those with the irregular sealing surface as compared to the cap sealing. This is due to the use of a rubber insert in the sealing head, which makes the foil adheres firmly to the container mouth.
- You save expenses on cap and liners.
Despite the above benefits, the machinery is heavily reliant on other auxiliary equipment, as shown below.
Here are the main sections of the equipment: sealing heads, reel holders, control panel, pneumatics, safety, generators, and foil feeds.
Besides, the capless induction sealer boasts of the following features:
- It comprises of a super seal segment.
- Capable of sealing a wide range of sized caps
- Direct contact induction sealing head.
- A touch screen human Interface for regulating the sealing parameters.
- Pick and place equipment.
- Location of vacuum foil
- Instant Startup and shut down button
4. Portable Induction Sealing Machines
Now, portable induction sealing machine category is broad and general.
It involves all the types of equipment that can be easily manipulated or moved to various work stations or areas.
Meaning, that they’re flexible and doesn’t necessarily need fixing in a specific location.
So portable induction sealers range from small handheld equipment to bigger sized ones.
Similarly, they’re easily customizable to include several features but again depending on customers specifications.
Portable induction sealing machine
Above all, you can get different operating machines, ie. Automatic, semi-automatic, or even manual portable induction sealers.
Here are the benefits of the sealer:
- It’s easily movable to several work areas( portable)
- Available in different designs and working mechanisms
- Simple operational/ control panel
- Available in several sizes and lightweight, easy to install and maintain.
- Relatively inexpensive compared to other types.
Aside from that, it suffers from the following shortcomings: most of them aren’t capable of high output production, some of aren’t suitable with a wide range of bottle heights.
Most of the portable induction sealers have simple and few parts.
The main ones include operation panel, cooling fan, induction head, induction coil, power adjustment buttons, sensing button, sealing switch, some have wheels, etc.
Finally, it has the sealer has these following worthy features:
- Stainless steel structure and cart, which makes it easier to clean and maintain even in rough applications.
- Compact and lightweight.
- Uses a wide range of voltage
- Adjustable sealing power.
- Simple, convienent and easy to use control panel.
- Standalone power supply and sealing coil, which thus eliminates any possible overheating of the power supply.
- Approved and standardized by CE, ETL, EMC, etc.
5. Automatic Induction Sealing Machine for Container Caps
Automatic induction sealer is rapid and highly efficient equipment due to the sophisticated technology that it uses.
Automatic induction sealing machine
Together with a PLC drive system, it produces excellent results and reliable performance.
Besides, the technology for use with this machine is dynamic and incorporates any change in the ever diverse tech world.
Some of the main advantages of automatic induction sealing machine include:
- Highly efficient, doesn’t waste power but minimizes energy consumption, and requires low power for most applications.
- Suitable for both low and high productions as well as outputs.
- It’s user-friendly. The digital control panel enables the user effortlessly to set up and configure parameters for fast changeover.
- Highly competitively priced.
- It is equipped with adjustable height and diameter to control various bottles.
- Adjustable power output and input.
Though, they’re reliable and efficient; these fully automatic induction sealers may be highly-priced compared to the manual ones.
Still, this kind of equipment become quickly outdated depending on the evolution of technology.
The main parts of this machine are: digital touch screen HMI, induction head, mains power, control, cooling fans, etc.
Some of the main features of the fully automatic induction sealing machine include:
- Adjustable power output according to conveyor speed.
- An entire self-automated process with sophisticated PLC.
- Standard stainless steel design.
- Ability to switch coil direction and diameters of sealing.
- Ultra compact thus requires minimum space.
- Most of them accommodate almost all container materials such as PE, PP, Metal, glass, PVC, PET, PS.
- Certified and of top quality.
- Some of them have got maximum power output and hi-tech microprocessor.
6. Induction Aluminum Foil Sealing Machine
The induction aluminum foil sealing machine is a class of all the equipment.
It applies a seal material made of precisely aluminum foil material and not any other onto the containers.
But of course, the procedure for this has to be through induction.
Now a combination of these machines includes:
- All handheld operated aluminum foil sealing machines
- Foot-operated aluminum foil sealing machines
- Conveyor type induction cap sealing machine
- Capless induction sealing machine, etc.
But remember the binding condition should be that; it only applies or seals an aluminum-based seal.
Benefits of induction aluminum foil sealing machine:
Similarly to other induction sealers, this category of the machine is applicable in pharmaceutical, food, beverages, cosmetics, lubricants, chemical and other plastic, glass together with other non-metallic packaging industries.
Moreover, the sealing material is of diverse range such as polyethylene (PE), polypropylene (PP), polystyrene(PS), ABS, polyester(PET), glass, etc.
Not that you can’t use the machine with metallic caps or bottles.
Likewise, induction aluminum foil sealing machines are available in different several designs and sizes; thus, you get to choose and select a proper one of your choice.
Most of them also have got a higher thermal efficiency of more than 90%.
Besides, these types of machinery are available in several specifications, depending on the needs and preference of the customers.
Drawbacks of induction sealing machine:
And obviously, the significant outstanding shortfall being the incapability of this machine to using metallic caps or metallic bottles.
Some of the main parts include inductor coil, sealing head, controls, mains power switch, etc.
Features of induction aluminum foil sealing machine:
- Some have fully automated working mechanisms, including excess current and excess voltage automatic protection system while others are manual, whereas some are semi-automatic.
- Stainless steel structure.
- Handheld designs are compact, versatile, and lightweight.
- Smooth operations.
- Long-lasting, highly efficient and little maintenance
7. Semi-automatic Induction Sealing Machine
Semi-automatic Induction sealing machine is technically almost similar to the automatic one.
However, the only apparent difference between the two is the class or category of the electronic grade for the machines.
Semi automatic induction sealing machine
Whereas semi-automatic induction sealer has got a semi-automatic kind of automated grade, a fully automatic induction sealer has an automatic class.
Advantages of semi-automatic induction sealing machine:
Semi-automatic induction sealer is capable of handling a small to the vast bulk of sealing operation without faults.
In terms of activity; the machine operates at a faster rate and suitable for handling a large output.
Besides, the equipment is easier to use, requires less maintenance, and simple to install.
You can as well employ the machine for use in pharmaceutical industries, food, chemical, cosmetic industries, etc.
Drawbacks of semi-automatic induction sealing machine:
On the contrary, the semi-automatic induction sealing machine is unsuitable for use with both metallic containers and caps.
Moreover, the sealer doesn’t smoothly operate for long periods under extremely harsh conditions such as high PH, high humid, and dusty areas.
Some of the common parts of this machine may include a digital control panel and HMI, induction head, power control, etc.
Features of semi-automatic induction sealing machine:
- Some designs have got microcomputer control, or digital PLC, therefore, they’re highly efficient and perform better.
- Power cut memory function that helps in regulating the electric power supply.
- Digital LCD screen.
- Counting pre-set functions
- Stainless steel structure and thus of high strength.
- Robust design. Some are simple handheld equipment, while others are sophisticated.
8. Bottle Induction Sealing Machine
Just as the name suggests, bottle induction sealing machine is suitable for applying an aluminum foil sealing to specifically bottles or jars.
However, that doesn’t mean it only has to be bottled for use with this type of equipment.
Benefits of bottle induction sealing machine:
Bottle induction sealers are efficient and perform better. Besides, they rapidly seal various sizes and diameters of bottles.
They’re also available in different designs and standards ranging from portable types to big and sophisticated designs.
In terms of pricing, you can easily find one at pocket-friendly costs.
Moreover, acquiring the replacement parts are locally available for the various bottle induction sealer models.
Drawbacks of bottle induction sealing machine:
Regardless of the wide variety of bottle induction sealers, the buying costs do shift or vary depending on the regions and locations.
So you do your research compare prices of different manufacturers before placing a quotation.
Besides, it’s unsuitable for use with metallic bottles.
Features of bottle induction sealing machine include:
- Easy to operate and efficient.
- The machine has all parts intact and therefore, noise-free.
- Digital touch panel
- Protective circuit capability against excessive current and overheating.
- Available in different operating systems; manual, semi-automatic, and automatic.
Main Components of Induction Sealing Machine
The sealers vary widely in design, operation, and size.
The diversity, therefore, translates into a difference in components and segments.
Nevertheless, some components stand-out.
In this section, we shall analyze the main components of the induction sealer.
But first, by analyzing the various machines, it’s evident that all the operations with the induction sealer revolve around power consumption and sealing.
Therefore, an induction sealer has two essential components:
- Mains Power supply
- Sealing head
Others minor parts include the control panel, inductive unit, PLC, generators, reel holders/compartment, pneumatics, etc.
Mains Power Supply of Induction Sealing Machine
The main power plug and cable transmits the electric power from the wall socket to an inverter.
Then, the inverter then regulates and transforms the incoming power into a suitable one for use by the machine to seal containers.
The inverter, in most cases, ensures the conversion of input power into DC power for the situation whereby the user plugs the equipment to an AC power input.
Again, the operational power demands of every induction sealer vary.
Always confirm the power rating of every machinery.
Power rating is vital since its that reading that indicates the suitability of a machine for a particular application.
Meaning, that a significant workload of containers that require sealing would translate into systems ever running and thus higher power rating — usually a couple of kilowatts.
Similarly, the hypothesis is correct for vice versa.
Take, for instance, most manual, handheld, or small portable systems consume power shy of 1 Kilowatt.
However, automatic, and other fast operating equipment require more kilowatts of power, some up to as much as 6 kilowatts.
That aside, for every piece of equipment, there’s a mains power supply cabinet from where you may tweak little things or make electrical connections.
Sealing Head of Induction Sealing Machine
The sealing head may be vast or small depending on the quantity of the containers that require sealing.
Elsewhere, the head comprises a continuous sealing coil.
As the aluminum foil, the sealing coil is an excellent metallic conductor located amidst ferrites but covered with an insulator mostly plastic.
The power supply in the inductive head initiates the inductive coil to emit electromagnetic current otherwise known as eddy current.
Furthermore, the neighboring ferrites are multiple, thus increasing the surface area for directing and blasting the electromagnetic field, making it highly efficient.
The coils are of different configurations, though, it doesn’t matter, it’s possible to use of any kind.
Normally, the two main designs being tunnel coils and flat coils.
Tunnel coils are preferably for use with dispensing, push-pull, Yorker, flip-top, or spouted kind of caps.
Such type of cappings though isn’t suitable for packing solid contents.
While flat coils are suitable for use with the inner seals or liners of ordinary flat caps with diameters ranging from approximately 20 millimeters to 120 millimeters.
You may also decide on the way to handle the coil by selecting from one of the two available options.
First, you may mount any of the two coil types on top of the already installed conveyor.
Or secondly, you can bind the system together by putting both the power supply and the coil on the trolley.
This is to enhance mobility through every line of operation.
Induction Sealing Machine Sealing Principle
We already know that the equipment utilizes the electromagnetic induction heating to seal containers.
Again, you have an option to select whether to seal capped bottles or if you want to apply capless applications.
Either case, the sealing procedure is more or less the same since all rely upon the use of electromagnetic induction heating.
Through non-contact induction heating, the liner material which may consist of a compound film of inductive film and aluminum foil.
They would tightly stick to the neck or the opening of the container after undergoing an instant thermal melting — thereby forming a tight seal.
Besides the above overview working principle, let’s consider the general way how the induction sealing machine works.
Cap Sealing Containers
For cap sealing, you will need caps with an aluminum foil liner.
Note that, aluminum foils are of numerous types usually, one-piece and two-piece kinds of liners.
The one-piece liners are purely foam-based, or paper-backed foil laminates.
Such that once the sealing process is complete, the whole inner seal remains stuck on the container.
However, a two-piece type liner has an added wax layer and pulpboard layer apart from the other one-piece liner materials.
The two-piece kind of layer is popular since it provides an additional improved sealing.
Therefore we shall consider it in our discussion.
Now assuming that the caps already got the liners, close the bottles with the caps.
The conveyor belt transmits the containers to the sealing head.
Thus the bottles pass beneath the induction coil.
The coil emits a robust and high-frequency electromagnetic field.
In turn, the conductive aluminum foil liner starts to melt as a result of the corresponding eddy currents.
The liner melts in a sequential manner, i.e. wax initially dissolves as it gets absorbed into the pulp backed layer thereby releasing the foil from the cap.
On the other hand, the polymer film layer heats up and pours onto the extreme opening of the container.
At this point, the air cooler blasts cold air onto the cap, subsequently, the polymer adheres to the lip of the container hence producing an airtight seal.
After all that, you now get a sealed container ready for packaging and shipping.
The whole process doesn’t interfere with the container nor the contents.
You can as well seal containers using small hand-held units, bigger units, or even a conveyor based system.
Instead of the air cooling systems, some types of equipment have got cooling water compartments.
Regardless of that, waterless( air cooling) sealers are increasingly popular compared to the corresponding water-cooling ones.
It is because waterless types are by far smaller, and doesn’t require the inclusion of water cooling auxiliary systems such as water circulators, water infiltrators, hoses, radiators, and pumps, etc.
Above all, air cooling induction sealers are more efficient, reliable, and less expensive.
Besides, we can’t eliminate the possibilities of the foil getting overheated, which may damage the liner and any protective layer.
In such circumstances, the seals become faulty.
That’s why you always need to ensure that you correctly input all the necessary parameters according to your application.
Moreover, choosing and buying a suitable induction sealing equipment may avert any potential sealing head faults that might hamper the seal integrity.
Capless Induction Sealing (Direct Application)
Capless induction sealing
Yes, with the recent development of technology, you can now seal some containers without necessarily providing closures (caps) with an induction sealing machine.
For this case, you need to supply a pre-cut foil or place the foil in a reel.
If you select to supply the foil in a reel, then the machine will die cut it and after that transfers it to the container neck.
Once the foil is in place, the sealing head presses it down, thereby initiating the induction process which ends when the seal adheres fully to the container.
So that’s an overview of the capless induction sealing or direct sealing technique.
Common Induction Sealing Problems and Solutions
Like other pieces of types of equipment, the induction sealing machine isn’t short of faults and troubles, especially during the sealing operation.
We shall, therefore, seek to identify the problems, state their potential causes, and find their solutions in this segment.
Here are the likely problems often reported by the machine users and the several various ways to troubleshoot them.
Machine Fails to Operate Even after Pressing the Hand Inductive Head Button?
- Likely causes: Faulty button switch
Solution: Consider replacing the switch.
- Likely cause: Power plug poorly connected.
Solution: Unplug and securely reconnect the plug.
- Likely cause: Inductive head possibly damaged
Solution: Substitute the inductive head with an efficient one.
Work Indicator doesn’t Light though the Power Supply Connection is Correct, and the Power Switch is ON.
- Possible cause: Defective fuse
Solution: Replace with a new fuse.
- Possible cause: Incorrect power plug connection
Solution: Unplug and reconnect the power plug securely.
Machine Doesn’t Seal the Containers Even Though the Work Signal Indicator is Operational.
- Possible effect: Short heating period of the inductive head.
Solution: Regulate, and if possible, prolong the heating time under the application.
- Possible effect: Damaged inductive head
Way out: Substitute the inductive head with an efficient one.
- Likely effect: Inconsistent inductive film materials and sealing objects.
Way out: Select a consistent inductive material with that of the sealing objects.
Sealing Film often Folds and Melts
- Likely effect: Long periods of inductive heating.
Possible solution: Shorten the period of heating appropriately.
Both the Spacer and the Film are in Contact or not Entirely Separated.
- Likely effect: Either too long or too short a period of inductive heating.
A possible way out: Modify the heating period appropriately.
Cardboard Liner Burnt
- Possible cause: conveyor moving too slow, or maybe excess power.
Solution: set the conveyor speed properly and adjust the power input.
Caps Too Tight and not Easily Removable
- Possible cause: inadequate sealing power.
Possible solution: properly adjust the power input.
- Possible effect: the coil set excessively high.
Way out: adjust the height of the coil appropriately.
Varying Seal Results
- Likely effect: inconsistent bottle lips, burrs, etc.
Possible solution: confirm whether all the caps are evenly torqued and not fully cocked before undergoing sealing.
Inadequate Sealing Power
- Likely cause: the metal guide rails very close to the sealing head.
Possible solution: ensure that the guide rails which are under the sealing head aren’t metallic.
Metallic materials affect the electromagnetic field.
Induction Sealing vs. other Types of Sealing
Besides, induction sealing, some users still makes use of different varieties of sealing methods.
And that’s what we shall focus on in this segment.
Let’s have a look at how induction sealing compares to other sealing techniques.
· Shrink Wrapping
Unlike induction sealing, shrink wrapping is quite straightforward.
It involves the process of covering an object or your product of any size or type with a shrink wrap.
Shrink wrapping – Image source: Brite
Applying heat then follows, the heat makes the wrapper to shrink, stick, and conforms to the shape of the product, thereby covering it entirely.
The usual way to apply heat is by use of a heat gun.
Besides, shrink wrap is a film for covering the products made from a variety of thermoplastic materials thus dynamic.
So basically you only need two things for shrink wrapping, i.e. shrink wrap and a heat source ( heat gun).
Although, with induction sealing, you require induction sealer, the containers, caps or liners.
The typical shrink wrapping applications are:
Industrial applications- here the wraps are of very thick polyethylene material.
Winterizing boats, covering bulky goods from weather changes are some of the uses of shrink-wrapping in this sector.
Shrink tubing wires-most manufacturers utilize shrink tubing to protect electrical wires together.
A butane heat gun is most preferred for heating and shrinking the cables.
You must have used some shrunk wrap products. Such common materials utilize: retail shrink wrapping, neck banding, shrink sleeves, shrink bundling film,
However, unlike shrink wrapping, induction sealing requires less heat and little packaging, it also consumes less room space, results in improved secure sealing.
Moreover, induction sealing is faster, especially for conveyor belt application.
· Conduction Sealing
Technically, conduction sealing is the use of a conduction sealer to seal the containers hermetically.
The procedure involves passing the bottles under a hot conduction head, a combination of heat and pressure, therefore securely seals the aluminum foil to the containers.
Conduction sealing process
It’s thus clear that unlike the induction sealing which utilizes a non-contact mechanism for sealing; conduction sealing the heated head must be in contact with the foil seal.
Still, before sealing begin with conduction sealing, the sealer head must first heat up for some time.
It is because the temperature sensors and heaters must activate, unlike the instant induction sealer.
The primary purpose for induction sealing is to enable the intense electromagnetic field heat up the foil seal.
Thereby activating and exposing the laminate material.
On the contrary, conduction sealing head heats the foil at high temperature to present the laminate material.
Elsewhere, induction sealing systems only consumes little power typically for most systems below 6kw.
While the conduction sealing systems guzzle a lot of electric power.
As opposed to induction sealing, heat sealing is generally the procedure of sealing two thermoplastic materials together by use of both thermal heat and pressure.
Heat sealing mechanism
Therefore, for heat sealing, you seal your products when capless or with no lid in place.
It is thus different from the induction sealing where you may require a lid/ cap or liner.
For heat sealing, you have to use a natural heat source that comes into contact with the bag or product to melt and dissolve the seal.
Same as conduction heating, you cant always begin sealing instantly with heat sealers, you have to wait for some period for the sealing systems to reach a specific temperature.
Therefore, extremely delays the process.
Unlike, the flexible induction sealing machine which can handle a wide range of sizes and shapes of containers; the heat sealer is rigid.
Also, it has several restrictions since you have to conduct change a few parts and designs.
With heat sealing, your products are always in physical contact with the equipment.
Therefore, it may lead to a lot of issues related to product handling and setting up.
However, for induction sealing, the procedure is explicitly non-physical contact hence no related physical handling issues and errors.
Other Support Equipment in Induction Sealing Process
To even access and reach out to the more advanced diverse market, manufacturers do perform several tweaks and modification to the existing machines.
This produces versatile induction sealing process.
That’s why most of them include other support systems in the sealing process.
Some of these support equipment includes:
Pick and Place System;
A couple of manufacturers opt to include an automatic piece of equipment that would literally hold and subsequently put the containers under the sealing head for electromagnetic induction sealing.
Conveyor Belt System
Sealing is even much more comfortable and faster with a conveyor system.
You only need to place the containers on the belt, and they will, in turn, flow directly to the sealing head.
In case of any operational fault or breakdown, the alarm system initiates either a flushing light (visual) or audible sound to alert the user.
So, you are in control of the process wherever you are.
Seal integrity detector; the system reliably senses any faults with the seals notably missing foils, trapped containers, firmly cocked caps during the sealing procedure.
Pneumatic Reject System
Such equipment works in collaboration with the seal integrity detector to remove any faulty sealed or unsealed containers direct onto a collection tray.
Thus, they don’t complete the sealing line.
How to Select a Suitable Induction Sealing Machine
Induction sealing machine
You realize that unsuitable induction sealer can instantly ruin and probably shatter your induction sealing aspirations and dreams.
Consider the following issues.
1) Decide Whether to Include an Inner Seal
Adding an inner seal will not only improve the overall quality of your packaging but also, in the long run, bring back your investment.
Remember the types of liners?
Note: it’s easier to seal plastic containers with plastic caps.
2) Evaluate the Machines’ Electronics and Availability of Spare Parts
A sealer’s types of electronics ultimately determine its’ durability.
Some equipment could last up to 30 years.
Also, go for a sealer that you can easily find its spare parts whenever the need arises.
3) Consider the Machines’ Technical Parameter, such as Sizes and Speed
It’s advisable to pick a system that’s big enough to handle a variety of container shapes and sizes.
Also, it should accommodate a high-speed production line.
Therefore, you won’t occasionally modify your system in case of changes in your output.
4) Compare Prices of Different Vendors
Before seeking price comparisons, have in mind the properties of the equipment you request, such as coil design, portability, power supply, etc such that you only compare prices for similar machine types.
For an accurate quotation, inquire from an expert.
5) Inquire about the Supplier’s Service/Provision of After-sale Services Support.
Will the supplier do troubleshooting?
Can they send a representative or over the phone?
Does the supplier distribute the power supply and sealing coil independently?
How about the access to spare parts?
How to Install Induction Sealing Machine
Installing an induction sealer is very straightforward, and therefore, you need not strain.
You can do it alone without the aid of a technician.
Consider the following steps.
i. Take note of the sealers dimensions.
ii. Preserve an adequate floor space which can accommodate it.
iii. After that, depending on the machine’s measurements, set out adequate straight floor space for mounting the sealing coil.
iv. Fix the sealing coil in a parallel direction to that of the conveyor.
Caution: to avoid unnecessary heating, always clear any metallic objects in or around the sealing region.
Uses of Induction Sealing Machine
The primary purpose for induction sealing machine is in making caps for containers mainly plastic and bottles to avert any chances of content leakages.
Induction sealed bottles
As we already mentioned, the caps also tamper-proof, preserve freshness amongst others.
While in the packaging industry, the induction sealer is vital in the fabrication of packages.
For example, in the formation of tubes from flexible materials, and fixing plastic closures to bags, etc.
On top of that, induction sealing machine is also applicable in sealing a variety of products such as those of pharmaceutical, nutraceutical, food, dairy, beverage, chemical, pastes, paints, dental, etc.
Ultimately, you already know every single detail about the induction sealing machine.
Weigh out the benefits of the equipment to those of other sealer types, and that should be enough reason to convince you.
Troubleshooting the equipment isn’t complicated either.
Above all, acquiring an efficient induction sealer would save you a lot of the hustle and bustle while in the long run returning your investment.