Package Evaluation Training3transversalsealing

22/09/2012 Package Evaluation T i i Training Transversal Sealing (TS Seal) PE-03/2012-04-01 Agenda Principle of Transversal sealing Evaluation - Tear down method + Practical Evaluation - Dissolving test method + Practical Evaluation - Heat Pattern + Practical Evaluation - TS integrity by red ink + Practical Example of TS defect PE-03/2012-04-01 / 22/09/2012 Principle of TS sealing li Transversal Sealing (TS Seal) PE-03/2012-04-01 Principle of TS sealing What we need to seal? Too short sealing time will affect proper heat diffusion through the polymer PE-03/2012-04-01 / 22/09/2012 Principle of TS sealing Polyethylene Sealing – Microscopic Scale PE-03/2012-04-01 / Principle of TS sealing General information on TS Sealing The heat required to melt the sealing layer of the packaging material is generated by induction in the aluminium foil in the packaging material ► TPIH sealing systems can produce short pulses with sufficient heat ► The heat is transferred directly to the sealing area ► PE-03/2012-04-01 / 22/09/2012 Principle of TS sealing Jaw System PE-03/2012-04-01 / Principle of TS sealing Definition PE-03/2012-04-01 / 22/09/2012 Principle of TS sealing Thermograph of Transversal Seal PE-03/2012-04-01 / Principle of TS sealing Induction Network PE-03/2012-03-01 / 10 22/09/2012 Principle of TS sealing TS sealing components TPIH 2000 TPIH 2500 Generator Transformer Inductor PE-03/2012-04-01 / 11 Principle of TS sealing TBA/19 – Component of the jaw system PE-03/2012-04-01 / 12 22/09/2012 Principle of TS sealing TBA/19 – Sealing jaw components PE-03/2012-04-01 / 13 Principle of TS sealing TBA/19 – Pressure jaw components PE-03/2012-04-01 / 14 22/09/2012 Principle of TS sealing Chain – Sealing jaw components Inductor Busbar Carbon Brush PE-03/2012-04-01 / 15 Principle of TS sealing Chain – Pressure jaw components Knife Spring Bushing Dolly PE-03/2012-04-01 / 16 22/09/2012 Principle of TS sealing Principle of ridge induction heating (IH) PE-03/2012-04-01 / 17 Evaluation - Tear d down method th d Transversal Sealing (TS Seal) PE-03/2012-04-01 22/09/2012 Evaluation - Tear down Evaluation concept The method consists of pulling TS (1) apart using the stretch pliers (2) and examining how the seal separates ► Seal must be mechanically stronger than the materials If the sealing g is g good,, the packaging material/strip layers (plastic film, Al-foil or paperboard) break while the seal does not separate ► Seal is stronger than materials PE-03/2012-04-01 / 19 Evaluation - Tear down Definition ► Blocked seal Blocked seals, or cold seal, is when the inner packaging material layers have not completely merged Separation takes place between the sealing layers ► Plastic lump Plastic lump is a plastic residue that solidifies out of the dolly area Plastic lumps are a potential danger, the hard residue might punch the packaging material layers during distribution of the package compromising package integrity PE-03/2012-04-01 / 20 10 22/09/2012 3.3 Dissolving method and practice Dissolving Method – SLOW (ALKALINE) Step 2/3: Rinse the samples under tap water and carefully separate the inner plastic bag The PM layers left at the end of the dissolving are the following; (5 – 6) Note! Do carefully at the corners when separating Make sure the Al-foil has dissolved completely; if not leave the samples in the solution a little longer or prepare a fresh one PE-03/2012-04-01 / 67 Dissolving method and practice Dissolving Method – SLOW (ALKALINE) Step 3/3 Dry the sample ! PE-03/2012-04-01 / 68 34 22/09/2012 Dissolving method and practice Drying the samples PE-03/2012-04-01 / 69 Dissolving method and practice Drying the samples PE-03/2012-04-01 / 70 35 22/09/2012 Heat Pattern E l ti Evaluation Transversal Sealing (TS Seal) PE-03/2012-04-01 Heat Pattern Evaluation TS heat pattern PE-03/2012-04-01 / 72 36 22/09/2012 Heat Pattern Evaluation PE-03/2012-04-01 / 73 Heat Pattern Evaluation TS Heat Pattern – Identify the ridge line Inductor ridge line and impression shadow Actual Inductor ridge line PE-03/2012-04-01 / 74 37 22/09/2012 Heat Pattern Evaluation Measure the heat pattern from correct ridge line PE-03/2012-04-01 / 75 Heat Pattern Evaluation Measure the heat pattern from correct ridge line Note! Bubbles in the heat pattern are typical for the twin Loop inductors They are located between the ridge and the product side look PE-03/2012-04-01 / 76 38 22/09/2012 Heat Pattern Evaluation Heat pattern & type of Inductor Sealing Technology : A loop close between two fins Single loop Twin loop PE-03/2012-04-01 / 77 TS integrity by Red i k test ink t t Transversal Sealing (TS Seal) PE-03/2012-04-01 39 22/09/2012 Plastic Bag Evaluation Red Ink Tighness PE-03/2012-04-01 / 79 Plastic Bag Evaluation How to measure plastic bag • Find the ridge line and measure from the red ink penetration 0.56 mm 43 mm 1.43 PE-03/2012-04-01 / 80 40 22/09/2012 Plastic Bag Evaluation Action This level must be a “STOP” for the production production Defective TS Seal Seal This level is “Monitoring or Stop for Action” depending on type of deviation Not defective TS seal This level is a “NORMAL” production Not defective TS seal PE-03/2012-04-01 / 81 Plastic Bag Evaluation PE-03/2012-04-01 / 82 41 22/09/2012 Plastic Bag Evaluation Monitor Insulated bubble in the sealing If the red ink does not pass through, the sealing is good It might indicate worn out inductor “Change Inductors” PE-03/2012-04-01 / 83 Hint on evaluation “Teeth” or “Product trap” toward cutting side Product trap, not knife problem Indication of knife movement problem Not critical, bubble d does nott follow knife pattern More critical, iti l as bubble follow knife pattern Reasons could be knife, gear box, spring, rubber bushing PE-03/2012-04-01 / 84 42 22/09/2012 Plastic Bag Evaluation “Change Inductors” Insulated long bubble in the sealing, close to the ridge If red ink does not pass through, the sealing is good It indicates worn out inductor PE-03/2012-04-01 / 85 Inductor Condition - Delamination or Detachment - Sink coil, check by measuring height of the ridge - Corrosion on coil, check by measuring height of the ridge PE-03/2012-04-01 / 86 43 22/09/2012 Plastic Bag Evaluation Check Inductor Check rubber bushing Insulated long bubble in the sealing If red ink does not pass through, the sealing is good In this case, the root cause is rubber bushing PE-03/2012-04-01/ 87 Rubber Bushing Condition - Check the rubber part is smooth and shiny - Both outer metal ring (3) and inner metal ring (4), not separated from the rubber part (1) - The inner metal ring (4) able to move up and down slightly PE-03/2012-04-01 / 88 44 22/09/2012 Plastic Bag Evaluation The seal shows show channels from the cutting area toward product side It can be related to bad knifes, knifes broken spring spring, rubber bushing and/or pressure related components PE-03/2012-04-01 / 89 Plastic Bag Evaluation PE-03/2012-04-01/ 90 45 22/09/2012 Plastic Bag Evaluation Product side PE-03/2012-04-01 / 91 Plastic Bag Evaluation PE-03/2012-04-01 / 92 46 22/09/2012 Plastic Bag Evaluation The seal shows bubbles and melted spots This indicates too high g setting g or p problem in the jjaw system The seal shows early bend-off Typically related to jaw pressure PE-03/2012-04-01 / 93 Plastic Bag Evaluation “Check Inductors/Knifes life time and condition, Change Inductors and Knifes ” Plastic bag with many insulated bubbles and long & repetitive teeth toward cutting Probably both inductors and knifes should be changed PE-03/2012-04-01 / 94 47 22/09/2012 Plastic Bag Evaluation Product Residue on the dog bone and knife • If the knife slot is dirty, it will hinder the movement of the knife and subsequently its position PE-03/2012-04-01 / 95 Example of TS d f t defect Transversal Sealing (TS Seal) PE-03/2012-04-01 48 [...]... PE-03/2012-04-01 / 32 16 22/09/2012 2 Evaluation - Tear down Evaluation of the samples Good seal The seal does not come part; the plastic film breaks leaving Al-foil uncovered PE-03/2012-04-01 / 33 2 Evaluation - Tear down Evaluation of the samples Good seal The seal does not come part; the plastic film stretch PE-03/2012-04-01 / 34 17 22/09/2012 2 Evaluation - Tear down Evaluation of the samples Defective... Tear down Evaluation of the samples Good seal The wave (1) is still encapsulated in the heated area and will not d t determine i integrity issues PE-03/2012-04-01 / 30 15 22/09/2012 2 Evaluation - Tear down Evaluation of the samples Good seal The seal does not come apart; the plastic film stretches and breaks, leaving the paperboard uncovered PE-03/2012-04-01 / 31 2 Evaluation - Tear down Evaluation. .. the package PE-03/2012-04-01 / 28 14 22/09/2012 2 Evaluation - Tear down Evaluation of the samples Defective seal “Plastic lump” Before pulling the seal apart, check that there are no plastic lump in the sealing Use your fingernails to detect plastic lump p p Plastic lumps (1) are a potential danger, hard residue might punch the PM layers during distribution of the package PE-03/2012-04-01 / 29 2 Evaluation. ..22/09/2012 2 Evaluation - Tear down Preparation of the samples – TS rough check Unfold the top and bottom flaps of the packages PE-03/2012-04-01 / 21 2 Evaluation - Tear down Check of the samples – TS rough check ► Checking the integrity of the TS by gently squeezing the package with the fingers ► If there is product leakage, the TS has a gross... practice Evaluation of the samples Defective seal “Blocked seal” The seal separates; no rupture occurs in the material layers The seal appears mattish or greyish greyish PE-03/2012-04-01 / 36 18 22/09/2012 2 Evaluation - Tear down Evaluation of the samples Defective seal - “Overheated” The seal is overheated; the two PE layers are burnt and the Al-foil shows micro cracks and cuts PE-03/2012-04-01 / 37 2 Evaluation. .. 22/09/2012 2 Evaluation - Tear down Preparation of the samples – TS accurate check St 1: Step 1 Cut C t off ff the th top t and d bottom of the packages at a distance of about 25 – 30 mm, from the top and bottom fin creases Rinse the samples and dry p them with either compressed air or soft tissue Note! Use compressed air with care since it might damage the sample PE-03/2012-04-01 / 23 2 Evaluation -... Good light is important when evaluation the seal quality PE-03/2012-04-01 / 26 13 22/09/2012 2 Evaluation - Tear down Check of the samples – TS accurate check Step 3: Stretch by pressing the plier handles along the whole length of the sample Stretch a little bit at a time, both ends (1) towards the LS/TS cross (3), stretch the LS/TS cross last last PE-03/2012-04-01 / 27 2 Evaluation - Tear down Critical... in order to have control over that important section PE-03/2012-04-01 / 24 12 22/09/2012 2 Evaluation - Tear down Check of the samples – TS accurate check Step 1: Run your finger over the TS and check if there are plastic lumps or ridges Plastic lumps show that the sealing is not correct PE-03/2012-04-01 / 25 2 Evaluation - Tear down Check of the samples – TS accurate check Step 2: Place the sample in... Dissolving packaging PE-03/2012-04-01 / 41 3 Dissolving method and practice Dissolving Package Purpose ► Information gained: − Monitor sealing components state and performance − Control settings over time − Monitor each sealing link over time − Allow archiving and traceability • plastic lumps • product residue p Evaluation of the samples • overheated seal • channels (unsealed spots) • cuts in the ridge... Bending off • sealing symmetry • abnormal heat pattern PE-03/2012-04-01 / 42 21 22/09/2012 3 Dissolving method and practice Preparation of the sample Step 1: ► Unfold all the flaps and flatten the packages Cut the package in a I shape, as shown in the picture (app 25 – 30mm, from the top and bottom fin creases) PE-03/2012-04-01/ 43 3 Dissolving method and practice Preparation of the sample Step p 2: ► Mark