Enercon Industries Limited

Cap Sealing Machine
Product Description

Cap Sealing Basics from a Global Expert:

Enercon is proud to be the world’s leading developer of induction sealing solutions. By combining our knowledge of induction sealing science, equipment manufacturing techniques and the unique application demands of the packaging industry; we are able to design in reliability and productivity better than any other cap sealing company in the world. 

Below are links to articles that clearly explain the basics of induction sealing for capped and capless containers, industrial uses for this technology, and tips on how you can achieve a perfect seal. If you can’t find what you are looking for please 
contact us

How cap sealing works
Induction cap sealing systems guarantee long-lasting product freshness. Induction cap sealers extend shelf life, reduce packaging weight, and ensure that complaints about leakages are a thing of the past. This non-contact process provides hermetic seals for bottles, jars and other container types. 

Containers with caps lined with an inner seal are exposed to a controlled Electro-Magnetic field generated by an induction coil. When the foil layer of the inner seal enters the Electro-Magnetic field a current is induced into the foil causing it to heat up. The heating of this layer activates a polymer or adhesive coating on the sealing surface. The cap’s on-torque is used to maintain pressure and contact between the sealing surface and the container rim so that when the liner cools the result is a hermetically sealed container. 

The structure of the inner seal can be a simple laminate consisting of EPE (Expanded Polyethylene), Aluminum Foil, PET (Polyethylene Terephthalate) and a Polymer / Adhesive layer or even more complex structures which include additional supporting layers of paper or foam bonded to the induction seal by a wax layer designed to melt and be absorbed during the heating process. Inner seals may also be printed on with a manufacturer’s logo, opening instructions or further advertising options. Because a foil seal is strong and flexible it can be used as a form of Tamper Evidence, as a broken inner seal can be designed to leave a residue that is easily detectable on the container rim.

Hand held and 
portable induction sealers can be used in labs for trials or for small production runs. High speed induction cap sealers are positioned over a conveyor and use sealing heads optimized for the container and cap configuration they are sealing.

This technology may also be used to seal containers without caps or caps without the required torque. 
Capless sealing systems use a pressure-belt or other means to secure the liner during the sealing process.

Benefits of capless sealing:

 
What profit squeeze? The savings are in your production process!
For many years products such as; food, milk, water, coffee, ketchup, yoghurts, pharmaceutical tablets, oils (olive & mineral), automotive brake fluid, household, healthcare, etc. have been foil sealed in variety of different ways. 

The high speed rotary table industry, lateral indexing lines, single shot and 2 head / 4 head / 8 head indexing tables generally use hot plate sealing heads for this function. However, this process has its limitations on speed and seal integrity, due to the hotplate heat sealer, time factor and the unregulated thermal and pressure control. 

Manufacturers are aware how critical it is that they operate modern production facilities due to the current uncertainty with the global economy. They are circumspect of unit cost, efficiency (especially with the escalating price of energy) and a continual rise in general overheads. All of which have an impact on a company‘s profitability. 

New regulations bring additional amounts of pressure on suppliers and contract packers to reduce packaging weight, reduce the use of energy, increase recycle ability and to become ever more efficient in their working practises -- and, in the short term, it is not predicted to get any easier! 

Manufacturers of Induction heat sealing equipment have recently provided a variety of sealing systems to improve efficiency and speed with varying degrees of success, but none, until now, have been able to take on the high speed lines in contact sealing due to technical limitations such as:
  • Reflected heat from the foil being sealed
  • Heating time cycle
  • Contact / Pressure
  • Foil thickness
Current rotary table units can run up to 450 seals per minute. However, the industry is keen on working towards 600 units per minute and a ”couple‘ of companies are nearly there! This means that the hotplate sealers are running out of heating time as the dwell time for the seal is now too long and is restricting the top speed that the fillers can be run at. 

A solution to the process of running a contact sealing head powered by induction energy has been found which will alleviate this situation posed by conventional hotplate. To realise the higher efficient line speeds, contact induction sealing heads need to be able to cycle at 40 units per minute 24 hours a day -- 360 days a year from one head. 

Enercon‘s development programmes have now achieved heat cycles of over 40 units per minute from one power source and just one induction head -- continuously. 

In trials some astonishing facts resulted:
  • A cycle rate of 40 units per minute equates to 1440 seals per minute on 36 head filler. (Not practical but achievable. In reality 800 to 900 units per minute)
  • The energy used by an induction contact sealer saves at worst 125Watts per head, per Kilowatt hour, over hotplate and possibly more.
  • Resulting in a 25% reduction in the use of energy.
  • Reducing CO. emissions and consequently carbon footprint by at least 25%.
  • The foil thickness can, in general, be reduced from 60 micron down to 20 micron -A saving of more than 50% on the amount of foil being used.
  • The sealing head and power unit can be retro fitted to existing lines.
  • The maintenance on induction contact sealers is substantially less than contact heating plates.
In fact everyone saves money and uses less of everything! But faster with a better quality seal and a much reduced unit cost of the product being packed.
 
Saving Foil
Halving the amount of foil required or used will save a massive amount of foil used and reduces the cost of the sealing process by up to 50%.
 
Saving Energy
The Induction contact sealing heads will save a tremendous amount of energy used in the process. For each head it is possible to save at least 125Watts of energy per Kilowatt hour or more per head. For every 1000 conventional heads that‘s equal to 125KiloWatts of energy saved every hour of every working day. Equal to 5MegaWatts per week and 24.MegaWatts per year and there are thousands of conventional hotplate sealing heads out there!
 
Saving Maintenance Costs
The Induction contact sealing heads require less maintenance, will outlast conventional hotplate heads and will give a much more controlled and superior seal without blistering or damage to the neck of the container being sealed.
 
Saving Waste
We cannot afford to waste product or packaging today! 

Investigate hermetic induction foil sealing and you will be amazed at the benefits and savings!

How to achieve a perfect seal
Your ability to achieve a perfect seal every time is directly related to your knowledge of the induction sealing process. A new technical paper explains the basic principles of induction sealing and provides you with techniques used by the pros to maximize line efficiencies. 

In this paper you will find:
  • 3 critical elements required to achieve a perfect seal
  • Insights on choosing the right liner for your application
  • Techniques used to identify a good seal
  • Step by step instructions on setting-up your induction sealing operating window

This paper will provide you with a vast amount of information to help you achieve a perfect seal. 

About Enercon:

 
Enercon Industries is the global leader in induction cap & capless foil sealing and Surface Treating Systems Technology.
We have over 30 years of experience in delivering reliable, state-of-the-art product and cost effective solutions. We are proud of the equipment we manufacture; knowing that our customers can be assured that they have bought the very best in high speed induction heat sealing and surface treating machines in the world.
Our worldwide network of representatives and distributors offers an unparalleled level of expertise for sales, service, technical support, training and consultancy across all Industry Sectors.
 
Our Commitment:
  • Enercon Industries is committed to manufacture and market our products to produce the very best value to our Clients.
  • Enercon Industries is committed to provide service and support on a world-wide basis; and through our network of Distributors we will endeavour to keep our clients sealing and treating production at capacity.
  • Enercon Industries is committed to reducing greenhouse gas emissions and can guarantee its machines are environmentally conscious

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