Packaging with Shrink Film usually applied to the desired product or item with heat emission. Packing process may have been carried out with various standards. For example, Shrink Film in the form of a roll will be placed in the packaging machine. Usually, a special mechanism that opens two layers of this folded film in the middle is designed on the machine. According to this design while the film is coming from a side, at the same time the product to be packed combined with a parallel speed and placed on the folding center. The film continues to wrap around the product that settled in this center and the three edges come to the stage of being welded.
It is commonly possible to close this film which one side folded itself and the other three are open in two ways:
- The first one is L Welding (L Sewing or L Cutting Machine, L-Sealer) and,
- The second one is Continuous Sealer (Side Sealer).
L Welding Shrink Packaging Machines
For the films which all three sides need to close, firstly one side should be closed with manual methods and then the rest of the two sides need to be closed. In this case, the other two edges are cut with the help of an L-shaped jaw. On the other hand, the wing corresponding to the front face of the next package is in the form of welded. This process can be repeated automatically again with the other two sides stuck.
Continuous Sealer Shrink Packaging Machines
Again for the films which all three sides need to close, they are subjected to continuous sealer by letting it pass through sewing machine rolls in the flow direction. In this way, infinite sealing will be ensured in the length. The remaining side will be sealed with the help of a vertical jaw with one-way weld. Continuous Sealer Machines are divided into two groups as intermittent and box motion or continuous motion. The products which are not be shaken by the hard stop and lift accelerations provide separate speed and size to box motion. As the package travels on the conveyor belt the jaw system syncs to the product at the same speed and performs the seal.
Choosing the Right Shrink Film and Shrink Machine
Firstly shrink film must be in proper specifications for proper shrink packaging. Also, the quality of the two-stage Shrink process depends on welding machine which makes a weld in the first phase and heat tunnel application which provides the right conditions in the second phase. The rate of shrinking ratio, heat level, the duration in the tunnel will result in a direct or inverse proportion to each other. In all of these processes, the quality of the shrink film has great importance as the shrink machine. The target is defined by the total quality:
Right, Shrink Film, right Shrink Seal Machine and right Heat Tunnel (Shrink Oven) should be in order to obtain a quality shrink packaging or packaging application.
Both sealing machine performance and a need for precision in tunnels can be reduced with a good shrink film. On the contrary, if you have a good shrink tunnel or you have quality weld – seal machine, again the same workload on the other legs may be reduced. But it is risky to trust only one of them. Especially working to cover the inadequacy of machine equipment by paying a high price for films will lead to increase in the total shrink cost by increasing the cost of a film while running away from machine cost.
From the perspective of investment and business, film consumption is a business expense. Whereas Shrink Machine is a long term investment item. As a result, low-quality machine and investment failure on the film will be continued to be suffered from each packaging. To be able to avoid this Shrink Packaging Machine should be bought once and attention should be paid to its potential to function at maximum with any films.
Shrink Packaging Automation and Benefits
The introduction of the shrinking concept into the sector has not been easy. Disagreements over the name are dominant;
Efficiency in Shrink Packaging
Today highly developed products are being exported to the market about Shrink Packaging Machines. Servo motor technology is in the middle of daily life. Very sophisticated products are being uncovered within great software and hardware traffic. Software with the mechanic or vice versa mechanic with software; “as known as mechatronics with the new term” embraced each other so that, programs and ideas are put in practice in the speed of light. Not only the shrink packaging machine itself; but also situations where it is necessary to control the whole phase from the arrival of the product itself, to delivery and labeling has been produced. Now the most intense part of our factory is the “project design” department. It’s almost as dense as the production department…
However, both Maripak is good ad manufacturing machines and production facilities have good packaging of the products they produce alone is not enough. The only part of the production is from the packaging process. The question of how much, how many shrink packaging is important. Their answer will show the departmental productivity and will be reflected in the unit cost. Production facilities have taken serious measures in recent years in spite of falling profit margins in parallel with developing production infrastructure. Almost all of the manufacturers needed to reduce production costs and re-consider their production efficiency. This is why packaging efficiency is very important!
Packing project which has an important place in the production process constitutes the latest phase of production. Unfortunately, there are serious losses in this process. Although manufacturers have serious knowledge and experience about the production of the products, there are serious shortcomings in this issue because they do not give the necessary importance to packaging. Worse is companies which manufacture are very insensitive for the calculation of labor and quality-related losses they incur in product packaging.
Shrink packaging has a great place within the context of “flexible packaging”. It finds itself in a wide perspective from food to automotive, textiles to stationery. Single-stage, “tunnel-less” Shrink Packaging Machines can be shown as the most amateur example of Shrink Packaging Machines. These machines have been a temporary solution for small and medium-sized companies for many years. However, there is a general consensus about the unfairness of expecting an industrial solution from a machine at this capacity.
It can be seen that the production capacities of domestic plants have reached serious points when considering any country’s population and export potential. Now all producers are working to eliminate the losses and measures are taken to increase productivity in accordance with the existing conditions of the competition market.
Common problems in packaging can be summarized as follows:
- Staff dependency
- Unit-time productivity losses
- Employment load
- Packing material losses
- Quality discrepancy
- Tracking cost of returning products from stores
- Damage to the brand
- Competition challenges
- Management and follow-up burden
- Losses due to unhealthy process flow
- Physical field losses in production
- Waste of used energy
Those who are looking for an automatic machine for the solution of these basic problems are often mistaken. As automatic machines are not a magic wand, they alone can not solve all problems.
The great pleasure experienced in Maripak Ambalaj in the years since the first automatic shrink packaging machine production in Turkey began and at least, thought it was the end for a while. However, the real automation has just begun.
Because it is not possible for an operator to feed the automatic machine with 100% efficiency. Even in the best conditions, it is necessary to calculate a feed-based loss of 20% in a hand-fed automatic machine. There are also “stop-and-go” losses in processes and simultaneous loss of labor. Therefore the product feeding unit in the packaging machine must be included in automation.
In the process that is common in the world, the product coming from the process line is taken out of the line before the packaging and then packaged in a different department. Products took from the production line and stacked need to be lined manually for twice and even more which is leading to the serious loss. It is very important to consider each hand intervention in terms of both product quality and productivity losses.
For example, it is extremely difficult to re-pack the eggs in a different stage after they are placed on the viol. However, if they can be delivered to the packaging machine on the line, serious operational facilities will be born. This situation which is common especially in food production causes the process to lengthen and limited shelf life.
There are differences in the shape to be packed in line with the arrival rates and physical postures of the products from the production line that will usually enter the packaging machine. They will have to enter the packaging machine by changing direction whether the products are either grouped or even one-on-one. Right at this point, the production efficiency will be changed with automation techniques to be used and it will take an integrated form and gain speed in the existing process.
Workers Passing Over to Auditor Operator
Shrink packaging is usually at the latest stage of the production process. It can be seen that the packaged product is once again packaged. In all kinds of production planning, the workforce used in this process is not included in general account and financials. The general target in the recruitment of personnel in the packaging department should be aimed at ensuring control of the system. So the main function of the employees must be control and follow-up. Workforce to be used in process packaging will be considered as potential error and “added-value” mechanical workmanship all the time.