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1. Will a machine with a Reynolds Sealing System seal Polyolefin?
Many lower profile products (1-4”) will seal on machines that have a Reynolds sealing system with a mushroom insert sealing a high quality Polyolefin shrink films. Some very low products (1-2”) will also seal on a machine with Reynolds sealing system with arrow inserts using high quality Polyolefin shrink films.
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2. Will heavy product run on any machine?
Heavy products weighing over say around the 2 to 3 lb. range will need to have special modification made to the conveying systems of that equipment. Some of the heavier products that are larger and spread the weight over a larger area can also be run. The product will have to be tested on the type of equipment that will be used in the production of the product in question.
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3. Are Hole punches the only way for air evacuation in a shrink film balloon?
Hole punches have been around for many years and can be still found on many machines. This is not the only way that air evacuation of the shrink film balloon can be accomplished. Pin perforating systems can be installed on most shrink film unwinds. Although many film companies such as (Cryovac) offers pre-perforated films. These films can be purchased with different configurations of hole patterns depending on the size and configuration of the product being wrapped. Cryovac charges no additional fee for this service. Many film sizes are stock items with standard hole pattern.
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4. What are the advantages of using high quality shrink film?
There are many advantages of using high quality shrink film a quality film will be much more constant. That is to say that the manufactures have good control of the processing of the film. The film formulation from one production of film to the next will be the same. The gauge of the film will be held closer through out the film web. The performance window will be much greater giving the shrink packaging production a much lower rejection rate. The lay flat of the film will also be maintained better. The lay flat of the film is very important for the tracking of film. The shrinking of the shrink film is much more consistent on good quality film which will yield better looking product. The clarity will also be much better.
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5. How do I keep light product from slipping on discharge conveyor belt?
Light product sometimes will slip on the discharge conveyor belts causing them to stay in the sealing area or in the discharge area. Check to see that the film in the sealing area is be cut. This can be cause from to low a heat setting, to low a dwell setting, not enough pressure being applied to the seal area, or if using a (hot knife system) the cutting blades may need to be replaced. Then check to see that the film is not sticking to the seal pad. This can be caused by the use of to much heat. Cleaning the Discharge conveyor belt can also help. If everything here is working ok then there is a light product hold down retro kit that can be purchased for many packaging machines. This device pushes down on the product to the conveyor belt to help it drive better.
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6. How do I keep the film from sticking to the inverting bars?
Most of the time Shrink films will stick to the inverting bars on packaging equipment because the film has polished the surfaces of the bars that the film runs over. The best way to fix this problem is by either sanding the inverting bars with very fine emery cloth or covering them with mold skin. Mold skin is used for preventing blistering on feet and can be purchased at any pharmacy. Using a harder film sometimes can help as well.
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7. How do I keep the film tracking properly?
There are two major reasons for film not tracking properly.
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The packaging machine is not set up properly or not working properly. First check that the machine set-up is done properly. Check to see that the film is going through the machine evenly that the film webs are under even pressure. Check to see that the film is not under to much tension. Film tension can cause most of the tracking problems on packaging machines. The film web should be taught but not overly tight. Check to see that the film is being driven properly.
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The shrink film that is being used has problems. Shrink film can also cause tracking problems. Check to see that the film is not blocked (the film layers should separate with out a lot of pressure). Check to see that the film is laying flat. Check this by unrolling about 10’ of film off the roll and try to hold it in air as tightly as possible. If the film is not flat then there may be a problem with the film. Call your film distributor for help.
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8. How can I keep my film from blocking?
Film blocking is generally caused by the film being stored in an area that is to hot. The best way to avoid this is to keep the film in an area that the temperature will not rise above 80 degrees Fahrenheit. Rotating film inventory can also help.
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9. What can I do to keep my film from tearing at the inverting head?
If there is to much film tension then this will cause the film to tear on the inverting head. Check to see the film is being driven properly through the film drive system. Check the film path and make sure that it is clean and free of debris. Also check to see that the film being used is the proper type.
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10 .What can I do to keep the film scrap from breaking at the film Puller?
The film is breaking at the film puller because there is possible to much tension on the film web. Check to see that the film drive system is working correctly. Check the film path and make sure that it is clean and free of debris. Check to see that the film is being cut properly at the seal jaw. Check to see that the scrap web is 1 to 3” wide depending on film type and quality. Also check to see that the film being used is the proper type.
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11. How can I make my shrink packaging look better?
The best ways to improve the look of shrink packaging is to; check to make sure that your not making the shrink bag to big. Check to make sure that the air evacuation system is working properly. Check to see that the film seals are complete and strong. Check the Shrink tunnel to see that the proper temperature for the shrink film that is be used is set properly. Check the speed of the conveyor belt going through the tunnel. Check in the shrink tunnel to see that the bag is ballooning and maintaining the balloon until it is just about out of the tunnel.
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12. Can I use a shrink film on cold or frozen products?
Shrink film can be used on most any product that is frozen (0 degrees centigrade). To use shrink packaging on frozen product the shrink package balloon has to be held off the product until the last second be for leaving the shrink tunnel. The shrink film will stop shrinking as soon as it touches the frozen product. This will leave the shrink packing appearance looking un-finish and wrinkled.
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13. Will the Shrink tunnel melt my product?
Most products will not have any effect to the temperature of the shrink tunnel. If the shrink tunnel is set up properly then the product that is being wrapped will not be in the heat of the shrink tunnel long enough to effect the product. This is because the product does not generally gain more than 10 degrees Fahrenheit when it is in the shrink tunnel.
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14. How often should the seal wires be cleaned on a shrink packaging machine?
There are a lot of factors that determine how often seal wires should be cleaned on a shrink packaging machine, here are some of them.
- The type of shrink film being used some shrink films can contaminate seal wires faster than others.
- Machine through put.
- Seal Wire temperature.
Generally if you check them once an hour and you find that the seal wires were not contaminated for say four hours. Then every four hours clean the seal wires. This should help to keep the seals on the shrink package strong.
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15. How often should I replace the tapes on seal beads of the shrink sealing machine?
The seal tapes on the sealing beads of shrink packaging machines should be replaced any time that they are starting to look worn, burnt, or cut. The best was to determine how often this should be done is to check the condition of the seal tapes every hour. Then if it takes eight hours for the tape to start to signs of ware then the tapes should be replaced every eight hours.
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16. Do I need to clean out inside my shrink tunnel?
The inside of the shrink tunnel needs to be cleaned out on a regular basis. At the end of every shift the tunnel should be inspected for any debris. If anything is found then it should be removed as soon as possible.
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17. Does it matter if the tunnel curtains badly worn or missing?
Having badly worn or missing tunnel curtains can make the tunnel temperature vary quite drastically making the quality of the finish shrink package vary. Also having badly worn or missing tunnel curtains will make the tunnel heating system work at lot harder to maintain the temperature setting. This will put a lot of stress on the heating elements and cost a lot more to operate.
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18. Why does the shrink tunnel (oven) not come up to temperature?
Some of the reasons that a shrink tunnel will not come up to temperature is because the tunnel curtains are badly worn or missing, the voltage going to the shrink tunnel is to low, or some of the heating elements are not working properly.
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19. Why does the shrink tunnel (oven) take so long to come up to temperature?
Some of the reasons that the shrink tunnel temperature is not rising fast is because, the tunnel temperature control system is not working properly, some of the heating elements are not working properly, or the curtains are badly worn or missing.
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20. Why is the temperature in the Shrink tunnel (oven) over heating?
The temperature in the shrink tunnel is over heating because the temperature controller or the temperature control system is not working properly.
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21. Why is the shrink tunnel (oven) not heating?
The reasons that the shrink tunnel is not heating could be because the heating control system is not functioning correctly, the heating control system is not turned on, the heating temperature control is set to low, or the heating element is burnt out.
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22. Why does shrink film stick together after going through the film separating rod on the shrink packaging sealer?
The reason that the film is sticking together is because the shrink packaging equipment is full of static electricity. Static charges can build up in shrink packaging equipment because of the shrink film running over the metal rollers and separators on the machine.
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23. How do I eliminate static charges from building up in the shrink packaging machine?
The best ways to eliminate static build up in the packaging equipment is to ground the machine to a cold water pipe, ground rod in the ground, or some other metal structure that is grounded. There is also equipment on the market that is available that inject an opposite charge in to film to keep it from sticking together.
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24. Why is the film tearing as it goes through the hole perforator?
The possible causes for film tearing as it goes through the hole perforator are:
- The perforation needles are dull.
- The perforation needles are set to deep.
- The perforation backing roller is in poor condition.
- The film that is being used is too hard.
- There is not enough film tension on film web.
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25. Why is the hole pneumatic hole punch not making a hole?
The possible cause for the pneumatic hole punch to not function properly are:
- The hole punch die is dull.
- The hole punch is not in alignment with die.
- The air pressure is to low.
- The air cylinder is not working properly.
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26. Why is the product tearing through the front seal of the shrink film?
Product is tearing through the front seal of the shrink film because the front seal is too weak, or the product is moving faster than the film. Slow down the infeed belt until the film and the product are moving at the same approximate speed.
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27. What can I do to keep product from getting stuck in the rollers of the roller conveyor in my shrink tunnel?
To keep product from getting stuck in the rollers of the shrink tunnel adjust the sealer height so the it is just higher than the tunnel height. Adjust the speed of the sealer discharge belt or the speed of the tunnel belt so that the tunnel belt is going slightly faster than the sealer discharge belt. Add additional rollers to the tunnel conveyor belt.
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28. How can I keep the Shrink film from curling my thin paper products?
There are special shrink films that are made for product that has trouble with curling. These films have a lower shrink force than other shrink films. Also some times the tunnel setting can be adjusted to help keep the shrink film from curling the thin paper products?
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29. How can I keep the shrink film from crushing my product?
If you shrink film is crushing the product you may need to look at shrink film that has a lower shrink force like Cryovac, D935. This type of film has a lower shrink forces than standard shrink films. If you are already using a low force shrink film then try; lowering the tunnel temperature, increasing the tunnel belt speed, or increasing the film containment size. Check the heat evacuation system and make sure that it is working properly.
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30. Why is the product getting stuck in the sealing area?
Product may be getting stuck in the sealing area because the product is to light and the discharge belt can not pull it away from the seal jaws. Make sure that the shrink film is being cut and seal completely. Adjust the seal temperature as low as possible but not so low as to keep the shrink film from cutting and sealing. A hold down device may also be needed to push the product down against the discharge belt.
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31. Why is the product lifting off the discharge belt when the machine is sealing the film?
Product is lifting off the discharge belt during the sealing cycle because the seal jaw center line is not centered with the product center line. Not having the product center and the sealing center set equally will cause excessive film tension and make it harder to seal shrink film.
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32. Why is the shrink containment on my product so wide?
Shrink containment size is being determined by how wide a containment that the machine is being set for. Adjusting the infeed as close to the film puller or side sealer will help to reduce the containment size. Also adjusting the film to the inverting head so that there is only enough film for the product height.
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33. Why is the shrink film containment on my product so long?
Shrink containment size is being determined by how long a containment that the machine is being set for. Adjusting the film prefeed and/or the product placement will help to make the containment smaller. Sometimes adjusting the belt speeds will also help.
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34. Why is the product hitting the film puller?
The film is hitting the side sealer because the infeed system is set-up improperly. Move the product further away from the film puller until it is no longer hitting the product.
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35. Why is the product hitting the front seal jaw?
Product is hitting the front seal jaw because there is not enough space between the film puller and the product for the height of the product and when the jaw closes it pulls the product into the sealing area. Adjust the infeed to create more space between the film puller and the product.
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36. Why is the product hitting the side sealer?
Product is hitting the side sealer because the infeed product guides are not adjusted properly and/or the side sealer is not adjusted properly.
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37. Why is the film on my film unwind over spinning?
Most film unwinds have some sort of braking capability. Usually the film is over winding because there is too little tension on the braking system or the braking system is not functional. Inspect the braking system and make sure that it is operational then increase braking tension in small increments until the film roll stops over winding.
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38. Why are the film drive rollers on my film unwind not pulling film when they are turning?
Film may not be pulling because there is something keeping the film from unwinding off the film roll. Maybe the film is caught on the separator bar. It’s possible that the drive roller and the pinch roller are not able to come together, check for obstructions. Inspect the condition of the drive roller, it may need to be cleaned or replaced. If the surface has been hardened over time then it should be replaced.
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39. Why the air flow in my shrink tunnel (oven) is seem lower than it was before?
Check the air flow path in the shrink tunnel. Inspect the screens of were the air is being draw from inside the tunnel. Check any air flow controls that the tunnel might have. Look for any air restriction that might be causing a blockage in the air flow. Clear any restrictions and test air flow.
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40. Why is the film being pulled back into the powered film unwind?
Film is being pulled back into the unwind because either the film has over wound and is under the film roll or the reversing switch is set in the wrong direction.
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41. Why is my side sealer not working properly?
Side sealers need to be keep clean and adjusted properly. First check to see if there is any film and/or debris built up inside the side seal unit. Then check the temperature adjustments check to see that they are set correctly for the speed of the machine. There are many types of side sealing units and many different problems that occur if you need further assistance please call.
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42. Why is my seal jaw not pulling down tightly on the shrink film?
If the sealing jaw is not pulling down tightly on the shrink film then it might be out of adjustment (automatic and semi-automatic machines). Check to see that all adjustments are made properly. If all adjustment is made properly then check that the system that is pulling the sealing jaws down is working properly (automatic and semi-automatic machines). Check to see that the system that is holding the seal jaw down is adjusted properly (semi-automatics & non-automatics). Also check to see that the seal jaw is contacting the seal pad evenly.
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43. Why is my seal jaw opening so slowly?
The reasons that might keep the seal jaw opening slowly are the adjustments in the exhaust restrictors are out of adjustment (over restricted). Check to see that the machine is getting the proper air pressure. Check to see that the air cylinder is functioning properly.
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44. Why is my seal jaw closing so quickly?
If the seal jaw is closing to quickly then check to see that the exhaust restrictor are not opened too much. Try closing the exhaust restrictor. If this doesn’t work check the air pressure and the condition of the air cylinder.
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45. Why do I hear air leaking out of my air cylinder?
Air cylinders as they start to get worn will start to have air blowing by the seals and causing air leaks. If this is the case then find out which air cylinder is leaking and replace it of repair it if possible.
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46. Why do I hear air leaking out of my air valve?
Air valve leaking is a sign of a worn out air valve or a worn out cylinder that has air blowing by seal on the piston. Replace worn devices as needed and test.
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47. What can I do to keep my sealer in good working order?
Keeping a sealer in good condition is an every day job. Everyday before the machine is started the machine should be cleaned and inspected. The machine should be cleaned and while cleaning all the sealing, film delivery and conveyor systems should be inspected. If any machine part is showing signs of wear then it should be replaced. Preventative maintenance is the best way to keep the sealing machine in good working order.
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48. What can I do to keep my shrink tunnel in good working condition?
Keeping a shrink tunnel in good condition is an every day job. Everyday before the shrink tunnel is started the inside of the tunnel chamber should be cleaned and inspected. The machine should be cleaned and while cleaning the heating and conveying systems should be inspected. If any machine part is showing signs of wear then it should be replaced. Preventative maintenance is the best way to keep the shrink tunnel in good working order.
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49. Why is the discharge conveyer on my sealer continuing to coast after the seal jaw has closed?
Discharge conveyer coasting is caused be cause braking system is not working properly. Inspect the braking system, check to see that the control system is working properly. Check to see that the brake is working properly.
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50. Why is the product getting stuck in the seal jaw and not returning up when the product is in the seal area?
Product is getting stuck in the seal jaws because the seal jaw safety system is not set up properly. Check to see that the jaw safeties are working properly. Check to see that the jaw safety over ride is not coming in to soon. May adjustments as needed and test to see that the system is working properly.
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51. Why is the seal jaw coming down to seal, but as soon as it touches the seal pad opens with out making a seal?
When the seal jaw opens as soon as it closes either the dwell time is set too low or the seal jaw safety system is not working properly. First check to see that the jaw dwell time is set properly. This should be (.5 to 5 sec.) depending on film and sealer. Next check to see if the jaw safeties are working properly. Make sure that the film clamps are moving freely; check to see that the safety switches or proxes are sending out an off and on signal to the control system. Check to see if the safety override is set properly. The safety override should come on just be for the seal jaw closes.
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52. Why is the Shrink film sticking to my seal jaw on the hot knife sealing system?
Shrink film maybe sticking to the hot knife because the coating on the hot knife has been damaged or the sealing temperature is too high. First check the hot knife condition. Check to see if has been damaged. Check to see if some of the coating has been removed. Then check to see if the sealing temperatures are set to high.
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53. Why is the film building up on my hot knife sealing system?
Shrink film maybe building up on the hot knife because the seal bar coating has been worn off. Possibly the temperature is set incorrectly. Some shrink films will not work on hot knife systems.
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54. How do I keep the Shrink film from sticking to my seal bars?
The best way to keep Shrink film from sticking to the seal bars is to run the sealing temperature at the proper temperature for the film being used. Also keeping the sealing bars as clean as possible will help to keep film from building up on the seal bars.
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55. Why does the sealing temperature have to be set higher than normal?
Sealing temperature may have to be increase due to poor sealing pressure. Check the condition of the sealing pads and seal bars. Check to see that adequate pressure is being applied in the sealing area.
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