Capless Induction Sealing New sealing technology providing performance improvements, significant cost &weight reduction opportunities and greater design flexibility
Benefits of Capless Induction Sealing Provides greater control over sealing process Allows immediate inspection of sealed container Rubber insert in sealing head delivers better compliance with uneven sealing surfaces than is possible with a cap Allows cooling of seal under pressure – better performance with hot-fill products Reduces cap and liner cost Use of new sealing technology provides opportunity for efficiency gains, cleaner production, improved visual appearance of product and enhanced consumer experience with easy to remove foil.
Conventional Conduction Sealing Hot, stainless steel sealing head Heat pattern on sealing head face Pressure & heat Heat conducted into foil cap 210°C Product
Conventional Induction Sealing Foil lined cap Cap torque presses foil against neck of bottle Foil heated through cap using electromagnetic waves Heat-seal layer melts and bonds foil to bottle
Capless Induction Sealing Ambient temperature sealing head Pressure Heat pattern on foil seal - only sealing area of foil is heated Heat insulation material 230°C Heat induced into foil where required to form the seal 21°C Product
Comparison Between Sealing Systems Conventional Induction Capless Induction Components expensive due to requirements of cap lining process & foil retention in cap Completely reliant on cap torque for sealing pressure (no control) Quality assurance difficult to verify as cap covers foil Restrictions on pack design due to cap/foil/thread fit Can use low cost reel-fed material and light- weight cap Sealing pressure mechanically applied so is reliable and measureable Foil can be subject to inspection processes after application With primary seal being formed by foil, significant flexibility over design of neck finish and closure is provided
Comparison Between Sealing Systems Conventional Conduction Capless Induction Inefficient, most of the energy put into the head is lost into the atmosphere Poor reliability with regular element & thermocouple failures due to high temperature levels within head whilst operating Difficult to control with temperature time-lag Workplace safety issues with hot surfaces No conformity with hard & irregular surfaces (ie PET/Glass ) Lost production with warm-up & cool down Highly efficient, only the foil seal is heated during the sealing process Extremely reliable since system is solid state and sealing head remains at ambient temperature with no thermal stress Precise digital control over energy input to head Extremely safe as no hot surfaces present Use of silicone rubber and other face materials to provide exact conformity with sealing surface Instant start-up and shut down for optimum availability
The Benefits of Capless Induction Sealing Increased Efficiency Electromagnetic heating within foil, no heat lost into environment Energy only used when machine sealing, zero consumption on standby Total Control Real time digital control over induction power level (temperature) Exact control of induction cycle time Precise control of pressure with rubber head insert for even conformity Ability to maintain pressure on foil during ‘cooling’ phase Measurement of induction power on each seal possible =100% QA validation Improved Productivity Significant reliability improvements as no heat is present in the components Instant start-up & shut-down Fast sealing cycle times Clean sealing Greater operator safety with cold sealing head
Examples of Capless Induction Sealing Metal Plastic Glass High Accuracy Non-Round Print Register