Package Evaluation

Training
Foundation

PE-01/2013/04/01

Agenda

1. Principle of Aseptic packaging

2. Packaging material
3. LS-Strip
4. Opening and Closures
5. Basic sealing information
6. Package terminology
7. Appendix – Tools and Chemical

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1. Principle of Aseptic
Packaging
Foundation

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1. Principle of Aseptic Packaging

Natural of Micro-organism

Source : Dairy Processing Handbook

TM-00816:2

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2
1. Principle of Aseptic Packaging
Aseptic food Processing & Packaging

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1. Principle of Aseptic Packaging

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 1. Principle of Aseptic Packaging
Commercial Sterility Definition
► There 2 kinds of commercial sterility definition as per
21CFR113.3 (1) Product ,(2) Equipment & Containers
1) Product
Definition

PE-01/2013/04/01 /7

1. Principle of Aseptic Packaging

Commercial Sterility Definition
► There 2 kinds of commercial sterility definition as per
21CFR113.3 (1) Product ,(2) Equipment & Containers
2) Equipment &
Containers

Reference: http://www.accessdata.fda.gov/scripts/cdrh/cfdocs/cfCFR/CFRSearch.cfm?fr=113.3

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 1. Principle of Aseptic Packaging
Food Packaging Role

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1. Principle of Aseptic Packaging

Critical Defect
The Transversal sealing is defective
The Longitudinal sealing is defective
The package allows passage of red ink to the paper board, in
to any portion defective

Tightness of packages can

be checked by three different
procedures:
-Tear down
-Conductivity*
-Dye-testing

*Apply for package with Al-foil, screening test

which need further verification with red ink test
when have positive reading.
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 2. Packaging material
Foundation

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2. Packaging Material
Structure

(Outside PE)

(Inside coating 1)

(Inside coating 2)

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2. Packaging material
TBA, TPA, TEA, TCA, TWA, TFA

LDPE
Print

Paperboard

LDPE
Al-foil
Adhesive Polymer
mPE

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2. Packaging material
Metallised packaging material structure TBA, TPA

LDPE Print

Metallised
LDPE OPP
film/Transp
arent OPP
film
Paperboard

LDPE
Al-foil
Adhesive Polymer
mPE

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 2. Packaging material
Metallised packaging material

Metallic appearance…

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2. Packaging material
Outside PE (TBA)

►Material LDPE
− LDPE Print

►Main functions
Paperboard
− Sealing (LS,
PullTab, PM splice,
Flaps)
− Moisture barrier
LDPE
− Print protection
Al-foil
Adhesive Polymer
mPE

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 2. Packaging material
Paper Board (TBA)

►Material LDPE
Print
− Liquid board

►Main functions Paperboard

− Print surface
− Stiffness
− Crease carrier
− Durability LDPE
Al-foil
Adhesive Polymer
mPE

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2. Packaging material
Laminate (TBA)

►Material LDPE
Print
− LDPE

►Main functions Paperboard

− Integrity Barrier
− Adhesive between
Paperboard and
Aluminium-foil LDPE
− Shock/Crack Al-foil
absorber Adhesive Polymer
mPE

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 2. Packaging material
Barrier layer – Aluminium foil (TBA)

►Material LDPE
Print
- Aluminium foil

►Main functions Paperboard

- Gas (oxygen) barrier
- Light barrier
- Aroma/Odour barrier
LDPE
- Part of sealing system
- Stiffness contribution PE/Adhesive Polymer
Al-foil
- Moisture barrier mPE

2. Packaging material
Inside coating 1 (TBA)

►Material LDPE
− LDPE mixed Print
with adhesive
polymer
Paperboard
►Main Function
− Integrity Barrier
− Adhesive
between
Aluminium foil LDPE
and Inside 2 Al-foil
Adhesive Polymer
mPE

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 2. Packaging material
Inside coating 2 (TBA)

►Material LDPE
− mPE (mixed Print
mLLDPE & LDPE)

Paperboard
►Main functions
− Sealing (SA, LS
and TS)
− Integrity Barrier LDPE
− Product protection Al-foil
Adhesive Polymer
mPE

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2. Packaging material
Function

1 Outside PE
2 Paperboard
3 Lamination
4 Al-foil
5 Inner coating 1
6 Inner coating 2
7 Product

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2. Packaging Material
Reel label
3 2 6

4 7

8
5

1 Customer name
2 Design number
3 Production Order Number
4 Reel number
5 Identification number
6 Production date
7 Number of packages
8 Volume/Size

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3. LS Strip
Foundation

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3. LS Strip
LS Strip structure

/LDPE

MPM Strip MWM /Wine MSE Strip

Strip
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3. LS Strip
LS Strip label

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4. Opening & Closure
Foundation

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4. Opening and closure

Ambient - openings, straws, flipcaps, srewcaps

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 4. Opening and closure
Pre-Laminated Hole (PLH)

OLD NNC
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4. Opening and closure

Closure portfolio Ambient application
Chilled application

*Milk only / 32
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 4. Opening and closures
PullTab Strip

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4. Opening and closures

Tab-Strip
PullTab Strips label

IS- Strip PEP OS Strip

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5. Basic Sealing
information
Foundation

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5. Basic Sealing information

Sealing Parameter

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5. Basic Sealing information
TBA – Generally Sealing application

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5. Basic Sealing information

TBA – Type of Sealing

TS LS SA PT Flap
A3 Speed/
IH IH IH IH/HP HA
TBA22
A3 Flex IH IH IH IH/HP HA
A3 Compact
IH HA HA IH/HP HA
Flex
TBA/8 IH HA HA HP HA

TBA/21 IH IH IH IH/HP HA

TBA/19 IH HA IH HP HA

IH -> Induction heating; HA -> Hot air; HP -> Hot Plate

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6. Package
Terminology
Foundation

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5. Package Terminology
TBA – Terminology

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5. Package Terminology
TBA – Terminology
Front side

Right
side

Left
side

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5. Package Terminology
Package corners term

TFL
T The first letter stands for top or bottom (T or B)
F The second letter stands for front or rear)
L The third letter stand for right or left (R or L)
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5. Package Terminology
TBA – Terminology

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Package Term
from OM

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 7. Appendix – Tools
and Chemicals
Foundation

PE-01/2013/04/01

Appendix : Recommended tools

TP Part no: 90243-0203

Note:
Part no. for Stretch pliers
- Small spring: 566772-000
- Big spring: 566773-000
- Pin: 78085-000
TP Part no: 78073-0101 TP Part no: 90243-0110
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Appendix : Chemicals

► Leak detection fluid - Red ink

► Dissolving solutions – Alkaline or Acid

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Appendix : Chemicals
Leak detection fluid – Red ink TP Part no. 90298-28

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Appendix : Chemicals
Leak detection fluid – Red ink

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Appendix : Chemicals
Leak detection fluid – Red ink

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Appendix : Chemicals
Dissolving solution – Acid (very fast method)
► Four different solutions are used :
1. HCl 1:1 Solution
2. HCl 1:3 Solution
3. Neutralizing Solution
4. For alternative method : Use HNO3 60-65%

► Ingredients :
1. HCl (37% - starting solution as commercially available)
2. Distilled water
3. CuCl2
4. Na2CO3 in crystals
5. For alternative method : Use HNO3 60-65%

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Appendix : Chemicals
Dissolving solution – Acid (very fast method)
Chemical preparation

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Appendix : Chemicals
Dissolving solution – Acid (very fast method)
Chemical preparation

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Appendix : Chemicals
Dissolving solution – Acid (fast method)
► Three different solutions are used :
1. Acid Solution – Hydrochloric acid
2. Neutralizing Solution
3. For alternative method : Use HNO3 30-33%

► Ingredients :
1. HCl (37% - starting solution as commercially available)
2. Distilled water
3. Na2CO3 in crystals
4. For alternative method : Use HNO3 (60-65% - starting
solution as commercially available).

Note: Chemical Concentration is % based on w/v

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Appendix : Chemicals
Dissolving solution – Acid (fast method)
Chemical preparation
1) Acid solution (Hydrochloric acid)
Prepare and acid solution of HCl 30% (e.g. for 3
litres solution put 600 ml of water in a beaker and
add carefully 2400 ml of HCl 37%).

2) Neutralizing solution
Prepare 10 wt% Na2Co3 in distilled water (e.g. 100 g
Na2Co3) and add water until the solution is 1 litre.

Note: Chemical Concentration is % based on w/v

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Appendix : Chemicals
Dissolving solution – Alkaline (slow method)

► Ingredients :
1. Distilled water
2. NaOH

Note: Chemical Concentration is % based on w/v

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Package Evaluation
Training
Package Forming and
Package defect name

PE-02/2014/06/01

Agenda

1. Date printing
2. Flap sealing
3. Weight
4. LS Overlap
5. Crease line alignment
6. Design
7. Package defect name

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Package basic conditions

The four basic package conditions are:

• Weight
• LS Overlap
• Crease line alignment
• Design position

All these conditions must be correct prior to any

package evaluation. Otherwise restore “basic package
condition”.

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Terminology Agreement

Symbol Description

Legal Requirement related check

Package Integrity related check

Package appearance and line efficiency

related check

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1. Date Printing
Package Forming

PE-02/2013/04/01

1. Date Printing
Check the date and code printing

How - Visual check

Why: Legal Demand
► Printed code is visible and
readable.
► Correct position/
information/code etc…
► Time on the package
should be the same as
time on the TPOP
► If necessary…. STOP the
filling machine and adjust
the date printing according
to the instruction supplied
with the printer.
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2. Flap Sealing
Package Forming

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2. Flap Sealing
Why
► Flap sealing effect the line
efficiency and package
integrity
How
► Unfold the flaps and
check that they are
properly sealed.
► On the bottom flaps the
heat should not be
directed on the TS.
► Burnt marks might impact
on package integrity.

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3. Weight
Package Forming

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3. Weight (Volume)
Weight the package - Why
► Legal demand
► Too high weight
increase product loss
► Too low weight could
effect package
forming and less
internal package
pressure which more
difficult for flap sealing

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3. Weight (Volume)
Weight the package - How

► Set zero the balance with the empty package.

► Weight the filled package, read the weights and record the
deviation if any. Correlate the weight to volume.
► To adjust the package weight, follow the instructions in the OM.
► Always check the weight again after adjustment
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4. LS-overlap
Package Forming

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4. LS-Overlap
Why
► Bymeasuring LS-overlap, can check the tube
diameter and packaging material width. These are
important parameters to produce well formed
packages
Distance B is
Overlap

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 4. LS-Overlap Refer to OM for Overlap
How distance, Example

►Use the vernier caliper or steel ruler

check the width of the overlap.
► If the overlap is out of the range
indicated, corrective actions should
be taken.
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4. LS-Overlap
Evaluation

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5. Crease Line alignment

Package Forming

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5. Crease line alignment

Why
► Visual inspection to verify
the creases are correctly
positioned. Incorrect crease
positions will have an
impact on package forming,
sealing, and could cause
mechanical tension.
How
► Unfold the top flap and
visual check for the crease
line alignment.
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5. Crease line alignment
Evaluation
Tube twist Good

< 1 mm
If the distance > 1 mm Adjust tube twist

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5. Crease line alignment

Evaluation

Tube twist - Left Tube twist - Right

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5. Crease line alignment
Evaluation

Overlap too big Overlap too small

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6. Design
Package Forming

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6. Design

Why
► Visual inspection to verify the packages are
correctly formed. Badly formed packages could
cause mechanical tension.
How
► Visual check the preformed crease in the
packaging material are correctly aligned along the
edge of the package (top transversal crease).

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6. Design
Fin crease terminology

Top fin distance

Bottom fin distance

• TBA 100 B and TBA 125 S, fin

crease = 6 mm
• Other sizes, fin crease = 8 mm

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6. Design
Evaluation
Check the shape of the package.

Check that the preformed creases

in the packaging material are
correctly aligned along the edges of
the package.

Grey, edge of
package, form by
the machine

Black, Preformed
creases in
Packaging material

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6. Design
Design position alternative
1. The easiest method for checking the correct design position is
to cut the package down the same as for a strip tear down test.

a) Collect 2 consecutive packages for checking

b) Cut each package down same as for LS/SA tear down
test, see below picture.

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6. Design
Design position alternative
2. Then looking at the insides of both the SA and LS pieces turn
one of them around so that the two pieces of strip are on the
same side, the top of one piece over the bottom of the other.

Measure distance A

To have good package shape and avoid integrity issue, package

should have top and bottom fins within 8 ± 1 mm, which is 7-9 mm
for 8 mm fin packages. For 6 mm fin, see Best practice chapter 8.
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 6. Design
Recommend of design error for 8 mm fin

Nominal Distance A = 0 mm Maximum Distance A < 2 mm

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6. Design
Recommend of design error for 6 mm fin

Nominal Distance A = 1.5 mm Tolerance Minimum A =1 mm

and Maximum A = 2 mm

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6. Design
Evaluation – Alternative method
► When it difficult to judge the transversal crease
position, can use alternative method
− Empty the package
− Cut from top to bottom of the package
− Compare the top and the bottom

• Design position is
correct since top and
bottom transversal
creases are align.

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6. Design
Evaluation – Alternative method

• Design position is too

low, since top and bottom
transversal creases are
mis-align.

• Design position is too

high, since top and bottom
transversal creases are
mis-align.

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 6. Design
Adjust the shape of the package

Note: Example, please refer to OM of specific machine

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6. Design
Adjust the shape of the package

Note: Example, please refer to OM of specific machine PE-02/2013/04/01 / 90

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7. Package defect name

PE-02/2014/06/01

7. Package defect name

Objectives

► To understand and aware of package defect.

► Able to give correct name to package defect when
communication.
► Package defect may only impact on the package
aesthetic and/or also result in package integrity
problem.

Note: Valid for TBA, TPA and TGA packages

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7. Package Defect
Index

► Forming defect ► Appearance defect

1. Pinching 13) Scratches
2. PPH torn and cloudy 14) Bottom scuffing
3. Corners fold 15) Crease dent
4. Corner collapsed a) Horizontal
5. Fin folding b) Vertical
6. Fin tears 16) Outside PE blister
7. Board crack 17) Squeeze from queing
a) LS crack ► Integrity
b) Corner crack 18. TS Al-foil crack
8. TS double folded 19. K-crease crack leakage
9. Wrinkle on/crossing TS
10. Wrinkle on opening area
11. Dented panels
12. Crocodile skin

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7. Package defect
1. Pinching - Forming

Definition:
Pinching is a
wrinkled on side
panel, where the
packaging material
is “pushed
together” and
originated from the
forming of a
package, normally
made by volume
flap or gap in
forming roller.
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 7. Package defect
2. PPH torn and cloudy - Forming
Definition:
The outside PE layer is torn/ruptured or cloudy in the PPH area
when weak adhesion between outside PE and laminate layer.

Torn Cloudy
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7. Package defect
3. Corner fold - Forming

Definition: A corner fold is a dimple or “negative folding” of

the corners, both top and bottom.

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7. Package defect
3. Corner fold - Forming

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7. Package defect
4. Corner collapsed - Forming

Definition:
A big corner fold with
double fold on the flap.
More sensitive in the
machines without crease
wheel and shallow crease
on packaging material.

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49
 7. Package defect
5. Fin folding - Forming

Fin folding occurs on top transversal seal when TS

bends on the reverse side creating a notable fold.

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7. Package defect
6. Fin tear - Forming
Definition:
A fin tear it’s a board crack that occurs where the top transversal
seal meets the flap at the end of the fin corner. The fibres must
be noticeable.

Cosmetic fin tear

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 7. Package defect
6. Fin tear - Forming

TBA TWA

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7. Package defect
7. a). LS Board crack - Forming
Definition:
The board cracks are visually detected and the fibres must be
noticeable. Board crack is located where the LS meets
horizontal top/bottom crease.

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51
 7. Package defect
7. b). Corner crack - Forming
Definition:
The board cracks are visually detected and the fibres must be
noticeable. A board corner crack is located on any of the eight
corners of the package.

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7. Package defect
8. TS double folded - Forming

Definition:
A folded line on a package where the PM should be smooth. TS
double folding can occur on the flaps of a package.

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7. Package defect
9. Wrinkle on/crossing TS - Forming
Definition:
A wrinkle on/crossing TS is a line on/crossing transversal
seal area.

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7. Package defect
10. Wrinkle on opening area - Forming
Definition:
Wrinkle on opening area can be small folded line where the
PM should be smooth or it can through the horizontal crease.

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 7. Package defect
11. Dented panels - Forming
Definition:
A package is classified to have dented panel(s) when one or several
panels are permanently deformed (dented) from its pristine shape. A
dented panel can be either pre-sent physical deformation or large
wrinkles on the panel indicating a previous deformation, which has
been squeezed back to shape.

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7. Package defect
12. Crocodile skin - Forming

Definition: crocodile skin defect is present when the surface of

one or more panels of the package is covered by wrinkles.

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54
7. Package defect
13. Out side scratches - Appearance
Definition:
Scratches are marks on panels that are notable mainly on
metallized packaging material

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7. Package defect
14. Bottom scuffing - Appearance
Definition:
Scuffing are holes or damages in the outer PE at e.g. the
bottom corners or the LS overlap, often due to wear from e.g.
the conveyor.

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7. Package defect
15. a). Crease Dent - Appearance
Horizontal Crease Dent
Definition: The crease is dented when the horizontal crease
(top or bottom) is clearly broken or when there is a wrinkle
through the crease.

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7. Package defect
15. b). Crease Dent - Appearance
Vertical Crease Dent
Definition: The crease is dented when the vertical (longitudinal)
crease is clearly broken or when there is a wrinkle through the crease.
The dent is located on any of the vertical creases, MD creases.

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7. Package defect
16. Outside PE blisters - Appearance

Definition:
Bubbles appearance on outside PE, damaged the package
appearance. Normally due to weak adhesion of outside PE.

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7. Package defect
17. Squeezing or queue
pressure marks - Appearance

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7. Package defect
18. TS Al-foil crack - Integrity

Definition:
Crack found on the ridge at TS seal and with early bending
off after dissolving

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7. Package defect
18. TS Al-foil crack - Integrity

Dissolved TS with no crack in the Aluminium-foil

High bend-
off

No channel

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 7. Package defect
18. TS Al-foil crack - Integrity

Dissolved TS with a crack in the Aluminium-foil

Early bend-off

Channel

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7. Package defect
19. K-crease crack leakage - Integrity
Definition: During forming bottom of package, tension is very
high where several layers of packaging material are folded.

Note : By nature, there always

have K-crack at bottom but not
leak by red ink test. Left side Right side
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Package Evaluation
Training
Transversal Sealing (TS)

PE-03/2014/06/01

Agenda

1. Principle of Transversal sealing

2. Evaluation - Tear down method + Practical
3. Evaluation - Dissolving test method + Practical
4. Evaluation - Heat Pattern + Practical
5. Evaluation - TS integrity by red ink + Practical
6. Example of TS Defect

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1. Principle of TS
sealing
Transversal Sealing (TS)

PE-03/2014/06/01

1. Principle of TS sealing
What do we need to seal?

Too short sealing time will affect proper heat diffusion through
the polymer
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1. Principle of TS sealing
Polyethylene Sealing – Microscopic Scale

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1. Principle of TS sealing
General information on TS Sealing

► The heat required to melt the sealing layer of the packaging

material is generated by induction in the aluminium foil in the
packaging material
► TPIH sealing systems can produce short pulses with
sufficient heat
► The heat is transferred directly to the sealing area
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1. Principle of TS sealing
Jaw System

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1. Principle of TS sealing
Principle of ridge induction heating (IH)

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1. Principle of TS sealing
Definition

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1. Principle of TS sealing
Definition

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64
1. Principle of TS sealing
Thermograph of Transversal Seal

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1. Principle of TS sealing
Induction Network

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1. Principle of TS sealing
TS sealing components
TPIH 2000 TPIH 2500

Generator

Transformer

Inductor
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1. Principle of TS sealing
TBA/19 – Component of the jaw system

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1. Principle of TS sealing
TBA/19 – Sealing jaw components

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1. Principle of TS sealing
TBA/19 – Pressure jaw components

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1. Principle of TS sealing
Chain – Sealing jaw components

Inductor

Busbar

Carbon Brush
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1. Principle of TS sealing
Chain – Pressure jaw components

Knife Spring
Bushing

Dolly

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68
2. Evaluation - Tear
down method
Transversal Sealing (TS Seal)

PE-03/2013/04/01

2. Evaluation - Tear down

Evaluation concept

► The method consists of

pulling TS (1) apart using
the stretch pliers (2) and
examining how the seal
separates.
► Seal must be mechanically
stronger than the materials.
If the sealing is good, the
packaging material/strip
layers (plastic film, Al-foil or
Seal is stronger than materials paperboard) break while
the seal does not separate.

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69
2. Evaluation - Tear down
Definition
► Blocked seal
Blocked seals, or cold seal, is when
the inner packaging material layers
have not completely merged.
Separation takes place between the
sealing layers.

► Plastic lump
Plastic lump is a plastic residue
that solidifies out of the dolly
area. Plastic lumps are a
potential danger, the hard residue
might punch the packaging
material layers during distribution
of the package compromising
package integrity.
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2. Evaluation - Tear down

Preparation of the samples – TS rough check

Unfold the top and bottom flaps of the packages

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70
2. Evaluation - Tear down
Check of the samples – TS rough check
► Checking the integrity of
the TS by gently
squeezing the package
with the fingers.
► If there is product
leakage, the TS has a
gross defect (most likely
a dolly is missing)

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2. Evaluation - Tear down

Preparation of the samples – TS accurate check

Step 1: Cut off the top and

bottom of the packages at a
distance of about 25 – 30
mm, from the top and
bottom fin creases.

Rinse the samples and dry

them with either
compressed air or soft
tissue.
Note! Use compressed air with care
since it might damage the sample.

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71
2. Evaluation - Tear down
Preparation of the samples – TS accurate check

Step 2: Cut off 1 mm max

from the edges (at the
corner).

Note: It is recommended to
start cutting from the outside in
order to have control over that
important section.

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2. Evaluation - Tear down

Check of the samples – TS accurate check

Step 1: Run your finger over

the TS and check if there
are plastic lumps or ridges.

Plastic lumps show that the

sealing is not correct.

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72
 2. Evaluation - Tear down
Check of the samples – TS accurate check
Step 2: Place the sample in
the stretch pliers and gently
squeeze the handles to
stretch the seal.

Good light is important when

evaluation the seal quality
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2. Evaluation - Tear down

Check of the samples – TS accurate check

Put and even Step 3: Stretch by pressing

pressure over the plier handles along the
the whole
package whole length of the sample.

Stretch a little bit at a time,

both ends (1) towards the
LS/TS cross (3), stretch the
LS/TS cross last.

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73
2. Evaluation - Tear down
Critical points of the transversal seal are:

1. The cross : which is the

point where the TS and LS
meet

2. The corners : which are

at the ends of the package.

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2. Evaluation - Tear down

Evaluation of the samples

Defective seal
“Plastic lump”
Before pulling the seal
apart, check that there
are no plastic lump in
the sealing. Use your
fingernails to detect
plastic lump.
Plastic lumps (1) are a
potential danger, hard
residue might punch
the PM layers during
distribution of the
package.
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74
 2. Evaluation - Tear down
Evaluation of the samples

Good seal
“Plastic wave”
The wave (1) is
still encapsulated
in the heated area
and will not
determine
integrity issues.

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2. Evaluation - Tear down

Evaluation of the samples
Good seal
The seal does not
come apart; the plastic
film stretches and
breaks, leaving the
paperboard uncovered.

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75
2. Evaluation - Tear down
Evaluation of the samples

Good seal
At the cross where TS and LS
meet, the LS must be
considered as additional plastic
multilayer.
Below picture shows the LS
which stretches and separates.

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2. Evaluation - Tear down

Evaluation of the samples
Good seal
The seal does
not come part;
the plastic film
breaks leaving
Al-foil uncovered.

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76
2. Evaluation - Tear down
Evaluation of the samples

Good seal
The seal does
not come part;
the plastic film
stretch.

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2. Evaluation - Tear down

Evaluation of the samples
Defective seal
“Blocked seal”
The seal separates; no
rupture occurs in the material
layers. The seal appears
mattish or greyish.

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77
2. Tear down method and practice
Evaluation of the samples

Defective seal
“Blocked seal”
The seal separates;
no rupture occurs in
the material layers.
The seal appears
mattish or greyish.

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2. Evaluation - Tear down

Evaluation of the samples

Defective seal - “Overheated”

The seal is overheated; the two PE layers are burnt and
the Al-foil shows micro cracks and cuts.
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78
2. Evaluation - Tear down
Evaluation of the samples

Good Seal - At corner, seal Blocked Seal - At corner, seal

above the ridge below the ridge
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This slide intentionally left blank

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79
3. Dissolving method
and practice
Transversal Sealing (TS Seal)

PE-03/2013/04/01

3. Dissolving method and practice

Introduction

► Procedure application:
− During production
− Quality control
− Troubleshooting

► Procedure:
− Chemical reaction, from the multilayer structure to the
inside pouch, via acid or alkali reaction
− Heat pattern assessment and red ink tightness of each
sealing jaw

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80
3. Dissolving method and practice
Dissolving packaging

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3. Dissolving method and practice

Dissolving Package Purpose

► Information gained:
− Monitor sealing components state and performance
− Control settings over time
− Monitor each sealing link over time
− Allow archiving and traceability
Evaluation of the samples

• plastic lumps • bending off

• product residue • sealing symmetry
• overheated seal • abnormal heat pattern
• channels (unsealed spots)
• cuts in the ridge area
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81
3. Dissolving method and practice
Preparation of the sample
Step 1:
► Unfold all the flaps and
flatten the packages. Cut
the package in a I shape,
as shown in the picture
(app. 25 – 30mm, from the
top and bottom fin creases).

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3. Dissolving method and practice

Preparation of the sample

Step 2:
► Mark each sample in
order to distinguish the
TOP and BOTTOM seal
after dissolution.

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82
3. Dissolving method and practice
Preparation of the sample

Step 2: cont…
► Cut with a distinctive cut
type (3) part of the
sample to identify from
which jaw pairs the
package comes

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3. Dissolving method and practice

Preparation of the sample
Step 3:
► If possible, cut the top of
the package using the
pinking scissors for an
easy identification of the
top. This step still remain
6 layers. (1 – 6)

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83
 3. Dissolving method and practice
Preparation of the sample
Step 4:
► Peel off the external
packaging (outer PE, a
part of PB layer will come
off). The PM layers left at
the stage on the sample
are the following: (2 – 6)

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3. Dissolving method and practice

Fast methods :
Use HCl acid

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84
 3. Dissolving method and practice
Alternative VERY FAST/ FAST methods : Use
HNO3 acid and alkaline NaOH
Alternative – Acid & Alkaline Alternative – Acid & Alkaline
agent (very fast) agent (fast)

- HNO3 60-65% - HNO3 30-35%

Solution
- NaOH 15% - NaOH 15%
used

- very fast (sample ready in 20 - fast (sample ready within 1

min) hr)
Advantages
- Room temperature, no need - Room temperature, no need
water bath water bath

- risk of spoiling of the sample - risk of spoiling of the sample

Disadvantages with too long immersion in with too long immersion in
solution solution

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3. Dissolving method and practice

Dissolving Method – Chemical Warning

Warning !
Risk of personal injury!
Observe safety regulations when working with ACIDS. Preparation
and handling of HCl, HNO3 and NaOH solutions must be carried
out in a well-ventilated environment, as fumes may be given off. It
should be carry out in an Exhaust cabinet. Always wear
protective goggles and gloves. Use heat resistant beakers for
preparation and storage. Exhausted chemical must be disposed of
in accordance with current regulations.

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85
3. Dissolving method and practice
Dissolving Method – Acid 1 VERY FAST (HCl)

Step 1/6:
Immerse the samples in HCl
1:1 solution one at a time for
approximately 4 minutes at
temperature between 55 –
60 C. Use a water bath.

Note! The temperature

settings might need
adjustments given the
equipment used.

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3. Dissolving method and practice

Dissolving Method – Acid 1 VERY FAST (HCl)

Step 2/6:
Remove the samples from
HCl 1:1 solution and
immerse them in the
Neutralizing Solution to
neutralize the acid.

Neutralizing Solution should

bubble as soon as the
samples are immersed; if
not, prepare a new solution.

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86
3. Dissolving method and practice
Dissolving Method – Acid 1 VERY FAST (HCl)
Step 3/6:
The external lamination layer
should easily separate from
the Al-foil by mechanical hand
action.
The inner plastic layers and
the Al-foil are left. The Al-foil
will be dissolved in the next
step.
The PM layers left, at this
stage, on the sample are the
following (4 – 6)
Note! Do carefully at the corners
when separating
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3. Dissolving method and practice

Dissolving Method – Acid 1. VERY FAST (HCl)
Step 4/6:
This the most sensitive step!

Immerse the sample into

HCl 1:3 solution, no more
than two at a time, until Al-
foil is dissolved . Keep the
sample in motion to reduce
the temperature.

The temperature of HCl 1:3

solution increase when the
samples are immersed into
it, therefore there is a high
! This bath is controlled risk of burning the package
at room temperature
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87
3. Dissolving method and practice
Dissolving Method – Acid 1 VERY FAST (HCl)

Step 5/6:
The Al-foil comes off. The inner
plastic bag, eventually isolated,
must be first neutralized in the
Neutralizing solution, then
rinsed carefully under tap
water
The PM layers left at the end of
the dissolving are the following;
(5 – 6).

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3. Dissolving method and practice

Dissolving Method – Acid 1 VERY FAST (HCl)

Step 6/6:
Dry the sample

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88
3. Dissolving method and practice
Dissolving Method – Acid 2 FAST (HCl 30%)

Step 1/4:
Immerse the samples in HCl
30% solution one at a time
for approximately 1 hour.

Note! Always use tongs to

immerse and remove the
sample from the solutions,
avoiding contact with hands.

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3. Dissolving method and practice

Dissolving Method – Acid 2 FAST (HCl 30%)

Step 2/4:
Remove the samples from
the HCl 30% solution and
immerse them in
Neutralizing solution to
balance acidity.

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89
3. Dissolving method and practice
Dissolving Method – Acid 2 FAST (HCl 30%)

Step 3/4:
Rinse the samples under tap water.
The external lamination layer and
the Al-foil should easily separate
from the inner plastic layer.
The PM layers left at the end of the
dissolving are the following; (5 – 6)

Note! Do carefully at the corners when

separating

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3. Dissolving method and practice

Dissolving Method – Acid 2 FAST (HCl 30%)

Step 4/4:
Dry the sample !

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90
3. Dissolving method and practice
Alternative Dissolving Method – Acid & Alkaline
VERY FAST / FAST (HNO3 & NaOH)

Step 1/5:
Immerse the samples in either HNO3 60-
65% solution (VERY FAST) one at a time
for approximately 7 minutes or HNO3 35%
solution (FAST) one at a time for
approximately 30 minutes.

Note! Always use tongs to immerse and

remove the sample from the solutions,
avoiding contact with hands.

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3. Dissolving method and practice

Alternative Dissolving Method – Acid & Alkaline
VERY FAST / FAST (HNO3 & NaOH)

Step 2/5:
Remove the samples
from the HNO3 solution.

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91
3. Dissolving method and practice
Alternative Dissolving Method – Acid & Alkaline
VERY FAST / FAST (HNO3 & NaOH)

Step 3/5:
Rinse the samples under
tap water. The external
lamination layer and the Al-
foil should easily separate
from the inner plastic layer
excepts Al-foil still is
present on sealing area.
Note! Do carefully at the corners
when separating

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3. Dissolving method and practice

Alternative Dissolving Method – Acid & Alkaline
VERY FAST / FAST (HNO3 & NaOH)
Step 4/5:
This the most sensitive step!
Immerse the sample into NaOH
15% solution until Al-foil (at
sealing) is dissolved,
approximately 8 minutes.
The temperature NaOH solution
increase when the samples are
immersed into it, therefore there
is a high risk of burning the
package.
Note! The sample should be immersed
all in NaOH solution, recommend 2
packages per 1 litre
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92
3. Dissolving method and practice
Alternative Dissolving Method – Acid & Alkaline
VERY FAST / FAST (HNO3 & NaOH)

► Step 5/5
Dry samples.

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3. Dissolving method and practice

Dissolving Method – ALKALINE SLOW (NaOH 15%)

Step 1/3:
Leave the samples in the
dissolving solution for at least
6 hrs. or until no Al-foil is
visible on the upper samples.

Note!
Leave the beaker uncovered to
allow hydrogen fumes to be
ventilated.
If fresh, the solution should
immediately start to bubble. If
not, prepare a new solution.

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93
 3.3 Dissolving method and practice
Dissolving Method – 3. SLOW (ALKALINE)

Step 2/3:
Rinse the samples under tap
water and carefully separate
the inner plastic bag.
The PM layers left at the end
of the dissolving are the
following; (5 – 6)
Note! Do carefully at the corners
when separating
Make sure the Al-foil has dissolved
completely; if not leave the samples in
the solution a little longer or prepare a
fresh one.

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3. Dissolving method and practice

Dissolving Method – 3. SLOW (ALKALINE)

Step 3/3
Dry the sample !

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94
3. Dissolving method and practice
Drying the samples

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3. Dissolving method and practice

Drying the samples

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95
4. Heat Pattern
Evaluation
Transversal Sealing (TS)

PE-03/2014/06/01

4. Heat Pattern Evaluation

TS heat pattern

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96
4. Heat Pattern Evaluation

PE-03/2013/04/01 / 193

4. Heat Pattern Evaluation

TS Heat Pattern – Identify the ridge line

Inductor ridge line and

impression shadow

Actual Inductor ridge

line

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97
 4. Heat Pattern Evaluation
Measure the heat pattern from correct ridge line

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4. Heat Pattern Evaluation

Measure the heat pattern from correct ridge line

Note! Bubbles in the heat pattern

are typical for the twin Loop
inductors. They are located between
the ridge and the product side. look
PE-03/2013/04/01 / 196

98
4. Heat Pattern Evaluation
Heat pattern & type of Inductor
Sealing Technology : A loop close between two fins

Single
loop

Twin
loop

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This slide intentionally left blank

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99
5. TS integrity by Red
ink test
Transversal Sealing (TS)

PE-03/2014/06/01

Plastic Bag Evaluation

Red Ink Tighness

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100
Plastic Bag Evaluation
How to measure plastic bag

• Find the ridge line and measure from the red ink penetration

0.56 mm

1.43 mm

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Plastic Bag Evaluation

Action

This level must be a “STOP” for

the production. Defective TS Seal.

This level is “Monitoring or Stop for

Action” depending on type of
deviation. Not defective TS seal.

This level is a “NORMAL” production.

Not defective TS seal.

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101
Plastic Bag Evaluation

PE-03/2013/04/01 / 203

Plastic Bag Evaluation

Monitor With Deviation

Insulated bubble in the sealing. If

the red ink does not pass through,
the sealing is good. It might
indicate worn out inductor.

“Change Inductors” With Deviation

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102
Hint on evaluation “Teeth” or “Product
trap” toward cutting side
Not critical,
Product trap, not knife problem
bubble
does not
follow knife
pattern

Indication of knife movement problem

More
critical, as
bubble
follow knife
pattern

Reasons could be knife, gear box, spring, rubber bushing

PE-03/2013/04/01 / 205

Plastic Bag Evaluation

“Change Inductors”

Insulated long bubble in the sealing, close to the ridge. If red ink does
not pass through, the sealing is good. It indicates worn out inductor.
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103
Inductor Condition
- Delamination or Detachment
- Sink coil, check by measuring height of the ridge

- Corrosion on coil, check by measuring height of the ridge

PE-03/2013/04/01 / 207

Plastic Bag Evaluation

1.Check Inductor
2.Check rubber bushing

Insulated long bubble in the sealing. If red ink does not pass through, the
sealing is good. In this case, the root cause is rubber bushing.
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104
 Rubber Bushing Condition

- Check the rubber part is smooth and shiny

- Both outer metal ring (3) and inner metal ring (4), not separated from
the rubber part (1)
- The inner metal ring (4) able to move up and down slightly
PE-03/2013/04/01 / 209

Plastic Bag Evaluation

The seal shows show channels
from the cutting area toward
product side. It can be related to
bad knifes, broken spring, rubber
bushing and/or pressure related
components.

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105
Plastic Bag Evaluation

PE-03/2013/04/01 / 211

Plastic Bag Evaluation

Product side

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106
Plastic Bag Evaluation

PE-03/2013/04/01 / 213

Plastic Bag Evaluation

The seal shows bubbles and

melted spots. This indicates too
high setting or problem in the jaw
system.

The seal shows early bend-off.

Typically related to jaw pressure.

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107
Plastic Bag Evaluation

“Check Inductors/Knifes life time and condition,

Change Inductors and Knifes ”
Plastic bag with many insulated bubbles and long & repetitive teeth
toward cutting. Probably both inductors and knifes should be
changed.

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Plastic Bag Evaluation

Product Residue on the dog bone and knife

• If the knife slot is dirty, it will hinder the movement of the knife and
subsequently its position.

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108
 6. Example of TS
Transversal Sealing (TS)

PE-03/2014/06/01

Good Seal

Good seals, clearly see Good seals, rupture on

stretch of plastic strip layer

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109
 Good Seal
Twin loop Inductor – TBA 100B, 125 S

Plastic protruding at TS corners

TS Teardown sample TS Plastic bag

PE-03/2014-06-01 / 219

Good Seal
Twin loop Inductor – TBA 100B, 125 S
Bubble in TS product side

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110
Good Seal

PE-03/2014-06-01 / 221

Defective Seal - Finger

Generate from cutting side, passing the ridge to product side

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111
Defective Seal
Product smearing in TS with red ink leakage

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Defective Seal
Fibre passing through the ridge

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112
Deviation TS – Corrective action need
Bubble – Product coconut cream

PE-03/2014-06-01 / 225

Defective seal and Deviation TS

TS Al-foil crack (at ridge)

Not leaking Not leaking

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113
Red ink channel along strip edge
Consequence from dissolving
Typical in MSE strip when put in NaOH 15% > 10 hrs

Left in NaOH 15% > 24 hrs

PE-03/2014-06-01 / 227

Bubble : Consequence from dissolving

Typical in round shape and mainly locate on the ridge

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114
Package Evaluation
Training
Longitudinal Sealing

PE-04/2013/04/01

Agenda

1. Principle of LS and SA sealing

2. Evaluation – Visual inspection + Practical
3. Evaluation – Mechanical tear down + Practical
4. Evaluation – Red ink injection + Practical
5. Example of LS

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115
1. Principle of LS and
SA sealing
Longitudinal Sealing

PE-04/2013/04/01

1. Principle of LS and SA sealing

LS Strip Function

The Longitudinal Strip in Tetra Brik Aseptic system

has 3 main functions:

1) To prevent product absorption into the packaging

material edge
2) To improve the gas barrier properties of the longitudinal
seal area
3) To strengthen the longitudinal seal

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116
1. Principle of LS and SA sealing
LS Strip application - terminology

The strip applicator side (SA) of the seal is the strip

(2) is attached to the packaging material by the strip
applicator.
The SA is the side of the strip where the packaging
material (3) is double.

The Longitudinal sealing

side (LS) is the side of the strip
(2) where the packaging
material (1) is single.

An air gap (4) is present in the

middle of the seal.

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1. Principle of LS and SA sealing

SA Sealing

The Operations are:

1)The edge of internal surface of
packaging material is heated to
melt the plastic layer either by
hot air, or by induction heating.
2)The strip is laid on the surface
and pressed onto the
packaging material using
pressure rollers.
3) The SA is then made.

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117
1. Principle of LS and SA sealing
LS Sealing
The LS makes a tight tube of
packaging material just prior to coming
in contact with the filling product.
The flat PM (strip on one edge), is
guided into tube form.
The edge without strip is heating (hot
air or induction heating) by the
longitudinal element.
The heated edge meets the underlying
unheated one and the two are pressed
together between two rollers.
This sealing is achieved between the
inner and the outer surfaces of PM and
between the strip and the inside of the
tube.
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1. Principle of LS and SA sealing

Type of sealing system

Tetra Pak A3/CF hot air hot air

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118
1. Principle of LS/SA sealing
LS sealing component – Lower forming ring and LS
spring
LS Spring Lower forming ring

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1. Principle of LS/SA sealing

LS sealing component – Spring Force

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119
 1. Principle of LS/SA sealing
LS sealing component – Hot air and Induction
Heating

Longitudinal sealing Longitudinal sealing

Hot air Induction heating
PE-04/2016/06/01 / 239

1. Principle of LS and SA sealing

LS strip Application

The LS Strip application evaluation consists of three

steps:

1) Visual inspection of LS position and check of heat and

pressure distribution
2) Sealing quality check, by performing the mechanical
tear down of the LS Strip.
3) LS Strip tightness, by performing the red ink injection
test.

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120
2. Evaluation – Visual
Inspection
Longitudinal Sealing

PE-04/2013/04/01

2. Evaluation – Visual inspection

Preparation Sample

1.Unfold the Flaps of 2. Cut two opposite corners

package sample 3. Empty the package content
4. Cut the sample corner to
corner

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121
2. Evaluation – Visual inspection
Preparation Sample

5. Open up the sample,

rinse it with water and dry it.

PE-04/2013/04/01 / 243

2. Evaluation – Visual Inspection

Why Visual inspection

► By visually examining the LS, will get quick

indication if there are any malfunctioning sealing
components in the machine.
► Check for scratched, stretch marks, overheated
area and strip position.
► Use Zonoscope to examine heat distribution along
the longitudinal seal.

Note! Good light is important when

evaluating the seal quality

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122
2. Evaluation – Visual inspection
Strip Position

The LS strip is not always

centered with respect to the
seal. For MPM and MSE LS
strip types, 60-70% of the
strip covers the SA side or
̴ 4.2-4.9 mm.

Guideline : The air gap (4)

should be simply visible and
not exceeding 1.0 mm.
(practically not less than 0.4-0.5
mm to able to insert needle for ink
injection)

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2. Evaluation – Visual Inspection

Heat distribution by Zonoscope
X

TBA/lk TBA/jl
X

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123
 2. Evaluation – Visual Inspection
Heat distribution by Zonoscope

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2. Evaluation – Visual Inspection

Scratches mark

Defective
Deep scratches compromise package integrity
Check inside surfaces for scratches. Inside deep scratches might
cause package integrity problem, corrective actions should be taken.
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124
 2. Evaluation – Visual Inspection
Overheated, Blistering and Bubbles
Overheated Blisters Bubbles

Defective
Compromise package tightness
PE-04/2013/04/01 / 249

2. Evaluation – Visual Inspection

LS strip wrinkle / Fish bone
Defective - Compromise package tightness
Wrinkle in strip,
most likely due
to strip position
too much on LS
side. Too high
spring pressure
or temperature.

PE-04/2013/04/01 / 250

125
2. Evaluation – Visual Inspection
Overheated

Defective -
Compromise package
tightness

Excessive settings or
uneven pressure (LS
roller may not in control)
result in risk of affecting
the performance.

PE-04/2013/04/01 / 251

2. Evaluation – Visual Inspection

Blistering/Overheated

Defective
Blistering/Overheated
Check for any blister or
bubble along the heated
zone of strip.

The presence of blisters in

the LS or SA side of the strip
indicates too high
temperature or power
sealing setting

PE-04/2013/04/01 / 252

126
2. Evaluation – Visual Inspection
PE residue

Defective – Blocked
seal

PE residue
LDPE residue are
trapped below the strip
affecting the sealing

PE-04/2013/04/01 / 253

2. Evaluation – Visual Inspection

Blocked seal

Defective -
Blocked seal

Strip and inside

PE not seal

PE-04/2013/04/01 / 254

127
3. Evaluation –
Mechanical Tear down
Longitudinal Sealing

PE-04/2013/04/01

3. Evaluation – Tear down

Preparation Sample

1.Unfold the flaps of package 2. Cut two opposite corners

sample 3. Empty the package content
4. Cut the sample corner to
corner

PE-04/2013/04/01 / 256

128
 2. Evaluation – Tear down
Preparation Sample

5. Open up the sample, rinse it 6. Cut the package sample along the
with water and dry it. middle of LS (1) and LS air channel (2)
Cutting line is (3)
PE-04/2013/04/01 / 257

2. Evaluation – Tear down

Tear down evaluation – Check Overlap

Pull off the outer Double

layer where it is layer not
double, overlap. complete
Check that the separate
overlap is
properly sealed
since is giving
strength to the
final package.
Double
Good overlap when the seal layer must
is even and rupture at least be
on outside PE layer complete
separate PE-04/2013/04/01 / 258

129
2. Evaluation – Tear down
Tear down evaluation – Bad/uneven seal Overlap

PE-04/2013/04/01 / 259

2. Evaluation – Tear down

Tear down evaluation – Good Overlap
Outer PE and some
Outer PE layer removed
fibred removed

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130
2. Evaluation – Tear down
Tear down evaluation – Good Overlap
Package with Metallised film (MF) or Transparent film (TF),
only outside PE will take out, not see paper board

TF Normal PM MF

Outer PE layer Paper board

removed removed
PE-04/2014/06/01 / 261

3. Evaluation – Tear down

Tear down evaluation – Check LS/SA

Pull the strip slowly

approximately 20 mm of the strip
outward at an angle of 90°.
Pull extremely slowly over the
creases.
Take hold again and pull
another 20 mm. Continue along
the whole edge.
Pull on both sides (SA and LS)

Note! If any of the layers come off,

cut the strip and start pulling again.

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131
3. Evaluation – Tear down

GOOD SEAL
Separation
between the two
inner coatings
When the strip is
pulled off and one of
the inner coating
comes off with the
strip (1) leaving a
rupture edge (2)
along the seal.

PE-04/2013/04/01 / 263

3. Evaluation – Tear down

GOOD SEAL
Separation
between the Al-
foil and the
inside coatings
When the strip (1) is
pulled off and the
two inner coatings
come off leaving the
Al- foil uncovered

PE-04/2013/04/01 / 264

132
3. Evaluation – Tear down

GOOD SEAL
Rupture in the
paperboard
When the strip is
pulled outwards
and all inner layers
including the Al-foil
come off with the
strip (1), leaving
paperboard fibres
(3)

PE-04/2013/04/01 / 265

3. Evaluation – Tear down

GOOD SEAL
Separation in
the LS strip
When the strip(1)
is pulled off and
one of the strip is
left on the
packaging
material. This can
happen also in the
cross, where LS
and TS meet.

PE-04/2013/04/01 / 266

133
3. Evaluation – Tear down

GOOD SEAL
Separation of laminate
Laminate PE PE
When all inner layers
including the Al-foil
come off with the strip
(1) leaving part of the
lamination layer (4) on
the paper board.

PE-04/2013/04/01 / 267

3. Evaluation – Tear down

Defective seal
Cold or blocked
seal
When the strip (1)
is pulled off and it
comes off leaving
the inner coatings
unaffected or with a
grayish surface.

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134
 4. Evaluation – Red Ink
Injection
Longitudinal Sealing

PE-04/2013/04/01

4. Evaluation – Red Ink Injection

Preparation of the sample

1. Unfold the flaps of 2. Cut two opposite 3. Open the

package sample corners. sample ,rinse it
Empty the package with water
content and cut the and dry it
sample corner to
corner.
PE-04/2013/04/01 / 270

135
 4. Evaluation – Red Ink Injection
Preparation of the sample

Be careful not to over stress samples during their preparation

PE-04/2013/04/01 / 271

4. Evaluation – Red Ink Injection

Procedure

► Inject 1 ml of red ink

into the air channel of
the LS with a 1 ml
syringe.
► The needle should be
around φ 0.4-0.5 mm
to get into the air
channel

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136
4. Evaluation – Red Ink Injection
Evaluation of the samples – Critical area

►Check that the strip is

tight and no Transversal
air channels are present

►Criticalpoints are
where the LS meet top
and bottom creases

PE-04/2013/04/01 / 273

4. Evaluation – Red Ink Injection

Evaluation

GOOD SEAL
“Deviation”
The Picture shows a
good seal , in which
the LS induction
heating setting is at
acceptable values.

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137
4. Evaluation – Red Ink Injection
Evaluation

GOOD SEAL
The Picture shows a
good seal, in which the
LS induction heating
setting is at acceptable
values.

PE-04/2013/04/01 / 275

4. Evaluation – Red Ink Injection

Evaluation

GOOD SEAL

The Red ink flows

straight in the air
channel and there are
no deviation

PE-04/2013/04/01 / 276

138
4. Evaluation – Red Ink Injection
Evaluation
GOOD SEAL
“Deviation”

This picture shows a

seal in which the ink
flow in the air channel
showing deviation that
are not compromising
package integrity yet.

PE-04/2013/04/01 / 277

4. Evaluation – Red Ink Injection

Evaluation

DEFECTIVE SEAL
“Channel leakage”
This picture shows a
seal in which the
deviation of the ink
in the air channel
are worsened
making a leaking
channel.

PE-04/2013/04/01 / 278

139
5. Example of LS
Longitudinal Sealing

PE-04/2013/04/01

Defective LS
LS blocked seal and Uneven heat pattern

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140
Defective LS and Deviation LS

LS Channel leak LS Channel deviation

PE-04/2014-06-01 / 281

This slide intentionally left blank

PE-07/2013-04-01 / 282

141
Package Evaluation
Training
Sealing window

PE-07/2013/04/01

Agenda

1. Introduction
2. Transversal Sealing (TS) window
3. Longitudinal Sealing (SA/LS) window

PE-07/2013/04/01 / 284

142
1. Introduction
Sealing window

PE-07/2013/04/01

Introduction
Seal in Tetra Pak Packaging System
Transversal
Front Panel Sealing strip
(TS) SA s LS

Longitudinal
Sealing
(LS)
External Sealing layer
Primer

Strip Applicator
Sealing Internal layer, usually PET
(SA)

Primer
Rear Panel External Sealing layer

PE-07/2013/04/01 / 286

143
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, 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-07/2013/04/01 / 287

What is a Sealing Window (SW)?

Example of LS sealing, hot air

Sealing window
Medium setting, 50% is
is from 180 ◦C to recommended to use
290 ◦C, medium in production
value is 235 ◦C

PE-07/2013/04/01 / 288

144
When is SW 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:

1. Filling Machine perfectly set following MM

2. Test methods
3. Trained personnel

PE-07/2013/04/01 / 289

This slide intentionally left blank

PE-07/2013-04-01 / 290

145
2. Transversal sealing
window
Sealing window

PE-07/2013/04/01

Transversal seal : Induction heating

Sealing jaw : Inductor

Pressure jaw : Dollies, Cutting rails, Knife, Spring, Rubber Bushing
PE-07/2013/04/01 / 292

146
Transversal seal evaluation
Tearing

PE-07/2013/04/01 / 293

Transversal seal evaluation

Dissolving

PE-07/2013/04/01 / 294

147
Transversal seal evaluation
Dissolving - Heat pattern evaluation

Note:
For 6 mm fin package
(TBA 80,100B, 125S);
B-measurement is
acceptable when > 0
mm

PE-07/2013/04/01 / 295

Transversal seal evaluation

Dissolving - Red ink tightness

PE-07/2013/04/01 / 296

148
TS sealing window
TPIH 2000 - 2500

► The setting range determined by the test is only 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,
mount new dollies.
► Check the cooling water flow through the inductors (for two
jaws machine).

PE-07/2013/04/01 / 297

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 5 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).

Note: Increase power setting can be >20 scu or >50 watt on middle value but
not at the lower of upper part.

PE-07/2013/04/01 / 298

149
TS sealing window
Test Execution – 2 jaws machine

► At each setting take out 10 packages (5 LH and 5 RH)

► Evaluate 2 LH and 2 RH packages (total = 4 packages per
setting) immediately with the stretch pliers, note the seal
quality in the test report
►Once the range is defined, take 1 LH and 1 RH (total = 8
packages) at the lower, middle, ¾ and highest setting to be
dissolved
Highest setting
3/4 setting

Middle
setting

Lower setting
PE-07/2013/04/01 / 299

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 4 packages immediately with the stretch pliers,
note the seal quality in the test report
► Once the range is defined, take out 1 sample per link (total
=10 packages) at the medium setting and evaluate
immediately with the stretch pliers to verify the uniformity of
the sealing quality among all the link.
►Once the range is defined, take 1 sample per each link
(total = 40 packages) at the lower, middle, ¾ and highest
setting to be dissolved.

PE-07/2013/04/01 / 300

150
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-07/2013/04/01 / 301

This slide intentionally left blank

PE-07/2013-04-01 / 302

151
3. Longitudinal Sealing
window
Sealing window

PE-07/2013/04/01

Longitudinal seal (LS)

SA LS PE-07/2013/04/01 / 304

152
Longitudinal seal evaluation
Heat distribution zonoscope

PE-07/2013/04/01 / 305

Longitudinal sealing evaluation

Tearing

PE-07/2013/04/01 / 306

153
Longitudinal seal evaluation
Ink injection to air gap

PE-07/2013/04/01 / 307

Longitudinal seal evaluation

Ink injection to air gap – Channel deviation

PE-07/2013/04/01 / 308

154
LS sealing window
Hot air/Induction heating

► The setting range determined by the test is only 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-07/2013/04/01 / 309

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.

Note: Increase temperature or power setting can be >20 scu/°C or >50 watt on
middle value but not at the lower of upper part.
PE-07/2013/04/01 / 310

155
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 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.
►Induction heating, for upper part, the length of wrinkle
must be < 15 mm.

PE-07/2013/04/01 / 311

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-07/2013/04/01 / 312

156
Package Evaluation
Training
Best Practice

PE-08/2013/04/01

Package Shape and

Design for TBA 125 S
(6 mm fin packages)
Best practice – S&SEA
Revision II – Dec’ 2011

PE-08/2013/04/01

157
 Content
► Objectives

► Scope

► Defect mode
► Possible causes
► Fin terminology
► Recommend Package Shape and Design

Note:
- This document intend to use for containment solution which
may replace once long term solution has been released
- Use of this document shall in combination with training

PE-08/2013/04/01 / 315

Objectives

►To increase awareness of package integrity risk

when TS seal (heat pattern) interference in fin
crease area
►To inform of the recommended package shape
and design for 6 mm fin packages

This document intend to use for containment solution which may replace once long term solution has been released.
Use of this document shall in combination with training

PE-08/2013/04/01 / 316

158
 Scope

►Valid for 6 mm fin packages

- TBA 80 S
- TBA 100 B
- TBA 125 S

►Valid for both standard inductor and twin loop

inductor which is more critical on twin loop
inductor

This document intend to use for containment solution which may replace once long term solution has been released.
Use of this document shall in combination with training
PE-08/2013/04/01 / 317

Defect Mode
► Leakage at bottom TS corner, inside the flap sealing
(app. 5 mm from corner)

Leakage Position on Packages

This document intend to use for containment solution which may replace once long term solution has been released.
Use of this document shall in combination with training
PE-08/2013/04/01 / 318

159
 Defect Mode, cont...
► Leakage at bottom TS corner and tear at the edge of
TS seal (toward product side)

Dissolved package

PE-08/2013/04/01 / 319

Possible Causes
1. High TS power: TS seal/heat pattern interference in fin crease area.
I. Typical TS power setting for A3 Speed 125 S is 1,100 -1,150 watt and on A3 CF is
1,000 watt.
II. Experience from trouble shooting, TS power setting on TBA/19 125 S 10V < 590 scu
and TBA/19 125 S 20V < 280 scu. For accurate setting shall verify with sealing
window.
2. Incorrect design: TS seal or heat pattern interference in fin crease
area
3. Double fold on the bottom flap corner, see pictures in next slide
4. Too high internal package pressure, must follow MM and check
by use the needle gauge
5. Over filling which increase internal package pressure, must ensure
correct product weight/volume
6. Direct heat in TS seal from bottom flap nozzle position

This document intend to use for containment solution which may replace once long term solution has been released.
Use of this document shall in combination with training PE-08/2013/04/01 / 320

160
 Possible Causes, cont…
► Double fold

PE-08/2013/04/01 / 321

Paper Tube
Fin Terminology
Packaging material – Crease pattern

Top

12 12 mm
mm
6 mm

Bottom

TBA 100 B and TBA 125 S have 6 mm fin

dimension (12 mm / 2 = 6 mm)

PE-08/2013/04/01 / 322

161
 Recommend Package shape and
design position for 6 mm fin packages
Black, Preformed Grey, edge of
creases in package, form by
Packaging material the machine

Low crease Correct High crease

position shape position

Wrong: Bottom fin Tolerable: Bottom fin = Recommend:

<6 mm 6 mm Bottom fin >6 mm
Maximum risk of TS High risk in combination with Reduced risk of TS
sealing up to bottom fin high TS seal power. Not sealing up to bottom fin
crease. recommended on twin loop crease.
inductor concept.
PE-02/2014/08/01/ 323

Recommend Package shape and design

for 6 mm fin packages
Bottom fin Top fin
6.5 mm 5 - 5.5 mm

Recommendation fin crease distance :

Bottom fin crease > 6.5 mm and Top fin crease < 5.5 mm

PE-08/2013/04/01 / 324

162
Package design vs Integrity: Quick look
Not Prefer – High Risk Preference – Low risk

Bottom Bottom

Not see fin crease See fin crease

Top
Top

See fin crease Not see fin crease

PE-08/2013/04/01 / 325

Package design – Seal up to bottom

fin crease : High risk for leakage

Bottom fin Seal up to bottom fin crease

5.5 mm

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163
Package design – Seal not up to bottom
fin crease : Lower risk for leakage

Bottom fin Seal not up to bottom fin crease

6.5 mm
Free
sealing
zone

Bottom fin
Crease

Average measurement 1 mm of free sealing

zone to middle of bottom fin crease

PE-08/2013/04/01 / 327

Accurate method to check package design

1. Take minimum two consecutive packages, cut packages down
the same as for a strip tear down test.
2. Then looking at the insides of both the SA and LS pieces turn
one of them around so that the two pieces of strip are on the
same side, the top of one piece over the bottom of the other.
3. Measure distance A as below picture.

Distance A should be > 1 mm to keep bottom fin crease distance longer than
top crease fin distance for 0. 5 mm.
PE-08/2014/06/01 / 328

164
 Recommend of design error for 6 mm fin

Nominal Distance A = 1.5 mm Tolerance Minimum A =1 mm

and Maximum A = 2 mm

PE-02/2014/06/01/ 329

Recommend of design error for 6 mm fin

A
A

Distance A > 2 mm, Not Distance A = 1 mm,

recommended Lower limit

PE-02/2014/06/01 /
330

165
Locate Contact to foil
position
Best practice – S&SEA
Revision I – Mar’ 2011

PE-08/2013/04/01

Content

► Objective
► Scope
► Equipment and chemical
► Method

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166
Objective

► Method to support trouble shooting during

production or trouble shooting package integrity
cases

Scope
► Usefor all package types where have Al-foil in the
packaging material structure

PE-08/2013/04/01 / 333

Equipment and Chemical

► Use the Conductivity meter and salt solution (NaCl

1%) as normal conductivity test
► Flexible wire
► Cotton bud, cotton, or tissue paper
► Clothes

PE-08/2013/04/01 / 334

167
Method
Preparing of cotton bud and probe

Cotton bud is used at the end of the probe

Cut the end of the cotton bud

as in picture. Use hollow
tube cotton bud.

PE-08/2013/04/01 / 335

Method
Setup for checking package

Ammeter with
wires

Cotton bud

Salt solution

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168
Method
Locate contact position

• Start with dry sample, put package in salt solution and end of
the bud wet with salt solution
• Check the close loop by putting the bud on the edge of package
and check if reading on the conductivity meter
• Move the wet bud over the suspected area
• Check if any conductivity reading PE-08/2013/04/01 / 337

Method - Alternative set up

• Attached the positive probe with cotton or tissue paper

• Dip it with salt solution
• Put bottom of the packages in the salt solution
• Put the cotton/tissue on the edge of package to check the ammeter
• Use the cotton/tissue tip to locate the rupture position
PE-08/2013/04/01 / 338

169
Package Evaluation
Training
Package Checking scheme

PE-09/2013/04/01

Agenda

1. Package checked overview

2. Package sampling and check - OM
TBA/19
A3 Flex
A3 Complex Flex
A3 Speed
….

Trainer to provide hard copy of

• “Package check” chapter for each type of filling machine from OM
to trainees
• TEM -1531354-0102 TBA/8, TBA/19, TBA/9 Laboratory Package
Checks

PE-09/2013/04/01 / 340

170
Package check
overview
Checking scheme

PE-09/2013/04/01

Package Checks – Overview

Date Print Laboratory check
Shape and Design
Conductivity test
Crease lines XX and Dye test
Overlap

Surfaces
Flap sealing
Laboratory check
Production LS/SA tear down

TS Dissolving
Weight XX
XX
TS rough

Production
TS: Tear down
Note:
Laboratory check xx = number of samples, at least equal to number
of jaw
* LS: Ink injection* * For A3/CF required 2 packages for normal
production and 10 packages after adjusting.

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171
TBA/19 – Package
sampling and check
Checking scheme

PE-09/2013/04/01

Package Checks
Production – OM

► For package checks at PRODUCTION start or at the

splicing of a new reel of packaging material, take 3
packages from the conveyor.
► Use the same two package to perform all the checks that
require two packages, the third package is used
specifically for the LS/SA check, patch or a tab strip splice.
► For package checks at the splicing of a new LS strip, patch
or tab strip reel, take 1 package from the conveyor.

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172
Package Identification
Production - OM

► When selecting packages, always select packages in pairs.

► When the jaw system is running, visually identify a
package made in one of the jaws. Press the DROP CHUTE
IN POSITION OFF button to eject one package, and not
which jaw made it. The first package which leaves the
outfeed conveyor after the gap was made in the other jaw.
► Mark RH on the package made in the right jaw. Mark LH
on the package made in the left jaw.

PE-09/2013/04/01 / 345

Checking Scheme Table

The Checking Scheme Table
explains:
• the events which it is recommended that the
package checks are performed immediately
after, e.g. Production Start (1)
• the number of packages needed according to
which event has prompted the package checks
(2)
• the number of packages on which to perform
the individual checks (3)
• the check to be performed (4)
• the page number of the check instructions (5)

• to mark the check box when the check has

been completed (6).

PE-09/2013/04/01 / 346

173
 PE-09/2013/04/01 / 347

Flowchart of the Production

Quality Checks

The Flowchart of Production Quality

Checks displays:

the checks to be performed in the

sequence described in the checking
scheme table (1)

the type of check (2)

the necessary actions (if any) to be
taken depending on the result of the
completed check (3).

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174
 PE-09/2013/04/01 / 349

Laboratory Check

► To perform the laboratory checks at least three

packages are needed. Two extra packages might
be needed if conductivity and dissolving tests are
to be performed in parallel.
► Checking scheme, see next slide

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175
 PE-09/2013/04/01 / 351

This slide intentionally left blank

PE-09/2013-04-01 / 352

176
A3 CompactFlex -
Package sampling and
check
Checking scheme

PE-09/2013-04-01

Package Checks
Production - OM

► For package checks at PRODUCTION start or at the splicing

of a new reel of packaging material, take 3 packages from the
conveyor.
► Use the same two package to perform all the checks that
require two packages, the third package is used specifically
for the LS/SA check, patch or a tab strip splice.
► For package checks at the splicing of a new LS strip, patch or
tab strip reel, take 1 package from the conveyor.

PE-09/2013-04-01 / 354

177
Package Identification
Sample packages
► To select packages and to be able to identify from which jaw
pair the package were formed, proceed as follow :

1. Touch the PRODUCTION CONTROL button

2. Touch the PACKAGE FORMING UNIT button

3. Touch the SAMPLE PACKAGE icon

4. Select the RH side or LH side which the first

package sample should be taken

5. Touch “ON” button to start the sampling of the

package

/
PE-09/2013-04-01
355

Package Identification
Sample packages

6. The jaw system discards a package.

Take the necessary package samples from

the conveyor after the gap created by the
discarded package.

Note! Touching the LH side will cause the jaw system to eject a
package from the RH side jaw leaving a gap in the package
outfeed to identify the LH side package.

/
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Package Identification
If 3 package samples have been collected
from the conveyor, use an indelible pen to
mark on the top and bottom of each of the
package samples as follows:
• mark the package made in the RH jaw
with the number 1 and the letters RH.
• mark the package made in the LH jaw
with the number 2 and the letters LH .
• mark the third package with the
number 3 and the letters LS.

If 1 package sample has been collected

from the conveyor, use an indelible pen to
mark on the top and bottom of the package
sample with the letters LS.

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Checking Scheme
The Checking Scheme Table
explains:
• the events which it is recommended that the
package checks are performed immediately
after, e.g. Production Start (1)
• the number of packages needed according
to which event has prompted the package
checks (2)
• the number of packages on which to
perform the individual checks (3)
• the check to be performed (4)
• the page number of the check instructions
(5)
• to mark the check box when the check
has been completed (6).

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 * Intended for every packaging
material reel

** To be performed at least one

per day (maximum interval of 24
hours) or according to dairy
internal quality procedures,
ideally one per shift. For the
packages integrity checks 2
packages our needed. If the LS
by Red ink injection check will
also be performed an additional
2 packages are necessary if the
machine settings are stable or
10 packages if the machine
settings have been recently
changed.

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Flowchart of the Production

Quality Checks

The Flowchart of Production Quality

Checks displays:

the checks to be performed in

the sequence described in the
checking scheme table (1)
the type of check (2)
the necessary actions (if any)
to be taken depending on the
result of the completed check (3).

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Laboratory Check

► To perform the laboratory checks at least three

packages are needed. Two extra packages might
be needed if conductivity and dissolving tests are
to be performed in parallel.
► Checking flowchart, see next slide

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