Package Evaluation Training 7 sealingwindow

26/09/2012 Package Evaluation T i i Training Sealing window PE-07/2012-04-01 Agenda Introduction Transversal Sealing (TS) window Longitudinal Sealing (SA/LS) window PE-07/2012-04-01 / 26/09/2012 IIntroduction t d ti Sealing window PE-07/2012-04-01 Introduction Seal in Tetra Pak Packaging System Front Panel Transversal Sealing (TS) SA strip s LS Longitudinal Sealing (LS) External Sealing layer Primer Strip Applicator Sealing (SA) Internal layer, usually PET Rear Panel Primer External Sealing layer PE-07/2012-04-01 / 26/09/2012 What is a sealing window (SW)? Just softening/overheating PE ≠ sealing it This statement is effective for all sealing technologies (IH; HA; US; CH) ► A SW is the range of energy required to have an acceptable sealing quality, starting from a lower limit = first setting giving a good sealing decreasing the energy the sealing gets blocked to an upper limit = last setting giving a good sealing increasing the energy the sealing gets overheated Applicable for Transversal sealing (TS), Longitudinal sealing (LS), Strip Applicator (SA), PullTab (PT),… ► The optimum is defined by the medium value of the range PE-07/2012-04-01 / What is a sealing window (SW)? Example of LS sealing, hot air Sealing window is from 180 ◦C to 290 ◦C, medium value is 235 ◦C Medium setting, 50% is recommended to use in production PE-07/2012-04-01 / 26/09/2012 SW: When is it required? ► ► ► ► ► ► New filling machine installation New production capacities New type of product (different viscosity, %fat, fibre, etc…) Product temperature change (impact on TS) Trouble shooting Etc… Basic Requirements: Filling Machine perfectly set following MM Test methods Trained personnel PE-07/2012-04-01 / Transversal sealing window i d Sealing window PE-07/2012-04-01 26/09/2012 Transversal seal : Induction heating Sealing jaw : Inductor Pressure jaw : Dollies, Cutting rails, Knife, Spring, Rubber Bushing PE-07/2012-04-01 / Transversal seal evaluation Tearing PE-07/2012-04-01 / 10 26/09/2012 Transversal seal evaluation Dissolving PE-07/2012-04-01 / 11 Transversal seal evaluation Dissolving - Heat pattern evaluation Note: For mm fin package (TBA 80,100B, 125S); B-measurement is acceptable when > mm PE-07/2012-04-01 / 12 26/09/2012 Transversal seal evaluation Dissolving - Red ink tightness PE-07/2012-04-01 / 13 TS sealing window TPIH 2000 - 2500 The setting g range g determined by y the test is only y valid in the conditions during the test and not as general working range for the filling machine ► If any comparison test need, it is necessary to run at the test same occasion and with the same conditions ► Filling machine must set according to MM and EM, the settings of the jaw system, e.g parallelism, are an important parameter to assure the final result of the activity ► Verify the conditions of the cutting rails and inductors, inductors mount new dollies ► Check the cooling water flow through the inductors (for two jaws machine) ► PE-07/2012-04-01 / 14 26/09/2012 TS sealing window Test Execution - General After machine ready in Production state, make a preliminary test to find the power setting of the TPIH unit for cold/blocked seal ► Run machine with the found value for about minutes in order to stabilize all temperatures ► Run at least 100 packages before collect packages sample ► Then increase the power setting by 10 scu or 25 watt for every trial until the upper limit found (plastic lumps, overheating swinging package) overheating, ) ► Note: Increase power setting can be 20 scu or 50 watt on middle value but not at the lower of upper part PE-07/2012-04-01 / 15 TS sealing window Test Execution – jaws machine ► At each setting take out 10 packages (5 LH and RH) ► Evaluate LH and RH packages (total = packages per setting) immediately with the stretch pliers, note the seal quality in the test report ►Once the range is defined, take LH and RH (total = packages) at the lower, middle, ¾ and highest setting to be dissolved Highest g setting g 3/4 setting Middle setting Lower setting PE-07/2012-04-01/ 16 26/09/2012 TS sealing window Test Execution – Chain machine ► At each power setting take out total 20 packages (2 packages per link) Make sure each package is marked with link number ► Evaluate packages immediately with the stretch pliers, note the seal quality in the test report ► Once the range is defined, take out sample per link (total =10 packages) at the medium setting and evaluate immediately with the stretch pliers to verify the uniformity of th sealing the li quality lit among allll th the lilink k ►Once the range is defined, take sample per each link (total = 40 packages) at the lower, middle, ¾ and highest setting to be dissolved PE-07/2012-04-01/ 17 TS sealing window Documentation Record P-order and reel no Record Filling machine information Record product and temperature ► Record all settings ► Attached form as example ► ► ► Microsoft Excel Worksheet PE-07/2012-04-01/ 18 26/09/2012 Longitudinal S li window Sealing i d Sealing window PE-07/2012-04-01 Longitudinal seal (LS) SA LS PE-07/2012-04-01 / 20 10 26/09/2012 Longitudinal seal evaluation Heat distribution zonoscope PE-07/2012-04-01 / 21 Longitudinal sealing evaluation Tearing PE-07/2012-04-01 / 22 11 26/09/2012 Longitudinal seal evaluation Ink injection to air gap PE-07/2012-04-01 / 23 Longitudinal seal evaluation Ink injection to air gap – Channel deviation PE-07/2012-04-01 / 24 12 26/09/2012 LS sealing window Hot air/Induction heating The setting g range g determined by y the test is only y valid in the conditions during the test and not as general working range for the filling machine ► If any comparison test need, it is necessary to run at the test same occasion and with the same conditions ► Verify conditions, alignment and setting of hot air elements/inductor, spring pressure according to MM, mount new LS pressure roller ► Check the overlap dimension and overall forming of the package produced, overlap and forming should be on package basic condition ► PE-07/2012-04-01 / 25 LS sealing window Test execution ► After machine ready in Production state, make a preliminary test to find the power setting of the lower limit by tear down method ► Let the filling machine produce for 10 minutes before test execution ► Run at least 100 packages before collect packages sample Then increase the power setting by 10 scu/C or 25 watt for every trial until the upper limit found (blistering/swing packages) ► ► Hot air - Each setting read the temperature and air pressure and note in the record, adjust pressure according to recommend setting in MM when increase temperature PE-07/2012-04-01/ 26 13 26/09/2012 LS sealing window Test execution, cont… ► At each setting take out 14 packages for evaluation ►Evaluate by manual tearing packages for each setting ►Evaluate 10 packages each setting by red ink injection to air gap, record the result in the test report ► Use zonoscope to check heat distribution, constant heat distribution along the seal length For lower setting, heat distribution should >2 mm from strip edge edge ► Induction heating, for upper part, the length of wrinkle must be < 15 mm PE-07/2012-04-01/ 27 LS sealing window Documentation Record P-order and reel no Record Filling machine information Record product and temperature ► Attached form as example ► ► ► Microsoft Excel Worksheet PE-07/2012-04-01/ 28 14 26/09/2012 E d End Sealing window PE-07/2012-04-01 15 [...]...26/09/2012 Longitudinal seal evaluation Heat distribution zonoscope PE- 07/ 2012-04-01 / 21 Longitudinal sealing evaluation Tearing PE- 07/ 2012-04-01 / 22 11 26/09/2012 Longitudinal seal evaluation Ink injection to air gap PE- 07/ 2012-04-01 / 23 Longitudinal seal evaluation Ink injection to air gap – Channel deviation PE- 07/ 2012-04-01 / 24 12 26/09/2012 LS sealing window Hot air/Induction... (blistering/swing packages) ► ► Hot air - Each setting read the temperature and air pressure and note in the record, adjust pressure according to recommend setting in MM when increase temperature PE- 07/ 2012-04-01/ 26 13 26/09/2012 LS sealing window Test execution, cont… ► At each setting take out 14 packages for evaluation ►Evaluate by manual tearing 4 packages for each setting ►Evaluate 10 packages each... forming of the package produced, overlap and forming should be on package basic condition ► PE- 07/ 2012-04-01 / 25 LS sealing window Test execution ► After machine ready in Production state, make a preliminary test to find the power setting of the lower limit by tear down method ► Let the filling machine produce for 10 minutes before test execution ► Run at least 100 packages before collect packages sample... Induction heating, for upper part, the length of wrinkle must be < 15 mm PE- 07/ 2012-04-01/ 27 LS sealing window Documentation Record P-order and reel no Record Filling machine information Record product and temperature ► Attached form as example ► ► ► Microsoft Excel Worksheet PE- 07/ 2012-04-01/ 28 14 26/09/2012 E d End Sealing window PE- 07/ 2012-04-01 15