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Danafilms Solves Sealability Problem
The inner layer of a bag structure needs to seal quickly
Overview/Context
When a bag does not seal properly, productivity goes down the drain. The inner layer of a bag structure needs to seal quickly and completely or product is wasted. Even worse, if ill-sealed bags reach the market, it takes a toll on the consumer’s perception of a brand’s quality. An ineffective seal layer wastes time, product, profits, and it damages your reputation in the market.
The Situation
The manufacturer of an over-the-counter health care product came to Danafilms with a sealability problem. The stand-up bags containing their product were not taking a good seal on the horizontal form and fill packaging line, which included attaching a zipper. Good sealability was required for both package integrity and attaching the zipper. They believed the problem was in the sealant film that was laminated to a reverse printed PET. In response to their request, we provided them with a higher quality, better sealing film than they had been purchasing from another film supplier.
The Challenge
The manufacturer tried the replacement film, but they continued to have the same problem. The manufacturer had not originally allowed Danafilms engineers to visit their facility, but now they relented. When the engineers were able to see the bags on the filling line, they discovered the real problem: The bags were sagging or flopping over as the bars came down to seal them. The sealing bars were not having contact at the exact location on the bags where it was needed.
The Solution
Our engineers went back to the lab and created a new blend of resins and additives to produce a stiffer sealant film. They tested this film in the lamination process and on the production line.
Results
The stiffer bags no longer flopped or sagged as they reached the sealing station. Not only did the manufacturer get bags that sealed properly, they were able to increase the line speed by 15% to maximize their machinery capabilities. The problem was corrected, and their productivity was improved.