Packaging Value

Innovative Development in Packaging

Replacing Heat Shrink Tamper Bands with Induction Seals Or Labels

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Heat Shrink Tamper Bands

Heat Shrink Tamper Bands

             Heat Shrink Tamper Bands

As a manufacturer using shrink tamper bands, you have the pain of actually applying shrink tamper bands. Machinery can be fickle; hand applying can be time consuming. It involves heat and it is, in general, quite a difficult process to implement and can be costly with materials.

On the consumer side of things, removing a shrink tamper band is quite a frustrating task for many who find it very difficult to see where to peel or where a perforation mark is on a clear tamper band. Both younger and older consumers can find it difficult to open a product with a tamper band that has been shrunk on.

The heat shrink tamper band also can lead to a lot of dust being  attracted to the product on the tamper band for reasons of static and also because the heat shrink tamper band produces a lot of edges where dust can collect and get under.

User Friendly Tamper Evidence Options

Induction Sealing

Induction Sealing

                         Induction Sealing

There are two relatively easy processes to implement in your production that can put tamper evidence on your product and also might get a much more user-friendly experience to open the product.

Induction sealing allows for you to put a foil across the top of your container, providing both tamper evidence and also a much better barrier property than a shrink tamper band. In most cases, you don’t need to deal with the induction sealing material; it’s already in the cap when you purchase it for your product.

Alternatively, you’ll be buying the induction sealing material in roll form, to apply with a cap less induction sealing machine or in pre-cut in smaller volumes to deal with cap less induction sealing.

Pressure Sensitive Labels

The other method is simply using a pressure-sensitive label with a little finger that might go over the cap or a small round or rectangular label that simply folds from the opening across and down the product. For example, a lot of pharmaceutical boxes will have a small, round and often transparent label that goes over the edge and onto the flap of the box that would open.

tamper evident labels

                      tamper evident labels

Jams and spreads often have a label that go either from above on the cap and right down the side of the container or they have a label that has, from the body of the label, on the round part of the product, it has a finger that extends and touches or goes over the top of the cap. In the case of labeling, the label has to be broken, typically, before the product can be opened; and that’s a form of tamper evidence.

Labeling equipment doesn’t require heat and the labels are easy to source and it’s much easier to order to automate or to semi automate than the heat shrink tamper band.

In summary, you’ve got two options to get rid of the heat shrink tamper band which is both a problem in production and a problem for the consumer: Method 1, Induction Sealing and Method two, tamper evident labels. Other options exist but these are by far the two most predominant and widely used options.

For induction options, you can look at the SealerOn website; for labeling options, you can look at the LabelOn website.

 

 

Labeling Machines: Versatile or Dedicated?

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This is about choosing between a dedicated labeling machine and a versatile labeling machine.

The LabelOn™ Labeling Range

In the LabelOn™ labeling range, there are two distinct in line machine ranges: The LabelOn™ Modular which is suited for versatile applications, where it can be expanded after being delivered to the client. The available modules on this machine enable most co-packer and private label projects to be handled, either as additional supply or future modules being supplied. The LabelOn™ Modular comes preconfigured with electronics, plugs and installed points, mounting brackets and positions all worked out.

A more dedicated line of labeling machinery is called the LabelOn™ Basic machinery. There are many shared features between the Basic and Modular including the basic electronics, motor drives and label heads.

LabelOn™ Modular and LabelOn™ Basic Label Applicators Comparison

Modular Labeling Machines

Modular Labeling Machines

The LabelOn™ Modular has a number of enhanced adjustments and additional electronics.  The most common labeling applications are labeling from above, labeling from above and below, labeling from the side onto flat containers or labeling from the side onto oval profile containers, that is, flat container where their sides have gotten an elliptical or oval type profile, a curve in one direction, much like a shampoo bottle. This type of labeling is often done from two sides. And there is round bottle labeling and that’s divided into three tasks:

  1. Single wrap label – which can be up to 100% wrap but typically between 50 and 85% wrap
  2. Two Labels on a round container
  3. Labels that are orientated on a round container with respect to a feature like a handle, bottle grips or even writing on a bottle; or possibly, another label

Any of these specific tasks can be achieved with a LabelOn™ Basic labeling machine. There will be a model suitable.

The LabelOn™ Modular range can cover everything, all, but a label from below. In which case, you would also get a LabelOn™ Basic machine to cover a top and bottom or just bottom labeling application.

LabelOn™ Basic Label Applicators for Dedicated Labeling Tasks

Basic Label Applicators

Basic Label Applicators

The LabelOn™ Basic machine, compared to LabelOn™ Modular for a dedicated task, is a more economic feature or more economic way to go. If you envisage, more than just a single, particular labeling task, then that would have to be achieved by one more LabelOn™ Basic machine; and probably can be achieved with just one LabelOn™ Modular machine, which would be lower cost than more than one LabelOn™ Basic machine.

LabelOn™ Basic 500 Left Hand Small Round and Small Rectangular Wrap
LabelOn™ Modular Label Applicators Profile

LabelOn™ Modular machine is a  longer machine; typically it is 12 feet or 3 meters long compared to LabelOn™ Basic machine which typically run between 6 and 10 feet or 2 to 2 ½ meters. The LabelOn™ Basic machine, as compared to other brand machines that do a single task, has a number of extra features and much better synchronizing usually of all the processors, all the conveyors, a coloured touch screen control and a machine that is really built for the task rather than bits and pieces put together to make up a machine that will do a single job.

The LabelOn™ Modular machine is truly a versatile and expandable machine and is unparalled in the market. It has a number of extra features on the basic including dual excess tilt on the labeling heads and a number of other under the hoods benefit that you will only find out after a long discussion with your LabelOn™ representative.

LabelOn™ Modular Label Applicator Walk Around

If you are a copacker, a contractor or simply a manufacturer with a large number of SKUs  and potential different product shapes, then, the LabelOn™ Modular is the best choice.  If you are moving into a higher scale production of a single or  range of shapes, then the LabelOn™ Basic represents a very cost-effective feature-packed option.

 

To Seal Using Induction or To Seal Using Heat Transfer?

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A common question raised is: when do I apply a heat transfer machine and when do I use an induction sealing machine?

Traditionally, you had no option but to heat seal when your product have no cap or closure that could tighten onto the body of the container. With the advent or development of capless induction sealing, the requirement for a cap is no longer there.  This is why there is the questions, when do I use induction sealing and when do I use heat sealing?

Below are two Capless induction sealing videos:

Low Volume Capless Induction Solution
Higher Volume Capless Induction Solution

Heat Sealing Explained

A physical constraint of heat sealing is the landing area where the sealing film will be applied and bond. Put simply, the landing area is the rim of the container and how wide that rim is. Where the rim of the container is less than 1/16th of an inch or about 1.6mm, induction sealing should be the preferred option. Heat sealing struggles with this thinner lip to seal onto.

You will notice on products like yogurt tabs, the sealing area has been turned up and may quiet wide often around a quarter of an inch or 45mm in width. This allows for a good area for the heat seal to apply.

And so we look the three areas: the cost of the material, the cost of the machinery, and the process – how easy it is to implement the machinery into your production.

Below is an example of a Turnkey Solution for Filling and Packing Creamed Honey Using Heat Sealing Technology.

Heat Sealing and Induction Sealing Material

The materials are broken up into foil line and just plastic film. Induction requires foil line, and therefore, is a more expensive material.  Even comparing foil line for heat seal, induction is generally a bit higher because it has more thickness to it for the induction process to work properly.

A foil within the sealing material, be it induction or heat seal, will provide much better oxygen and waste barrier properties. Because of the natural, thicker material in induction sealing, it’s also a material more likely to peel off cleanly in one piece compared to a heat seal foil.

Heat Sealing and Induction Sealing Price Comparison

In terms of machinery, both heat sealing and capless induction sealing have some similar properties. In the semi-automated machinery side of things, they both quite low cost and you can get equipment for under $10,000 USD.

For more automated where you need speed to 30 products and beyond, machinery becomes more expensive.  The machinery, in this case, requires cutting tools, to cut the material before placing it on the container’s sealing area. This represents a maintenance issue and also a cost issue. In both cases, equipment going for 30 products or more will cost at least $25,000 USD and often will go up to $80,000 USD.

Capless sealing could go beyond that and well into a $100,000 to $ 150,000 USD, when you are looking at 80 to 120 products per minute. Conventional induction sealing where the seal is placed into the cap prior to the cap being placed onto the product is much lower cost equipment. Each top induction equipment can start at around $1,500 USD. In line induction sealing usually ranges between $16,000 and $25,000 USD. Higher speed induction sealing where you might be looking at 150 products plus per minute can get up to about $40,000 to $45,000 USD.

Again, both in heat seal and capless induction sealing, you need to divide the products into a multiple lanes so that you can do the sealing at a reasonable rate of 30 plus to, say, a 120 products per minute. This adds to conveying costs and product movement costs and, indeed, the machinery costs. General advantage of induction sealing over heat seal are that the process can instantly, no time for waiting for the machinery to be ready. But with heat seal, you need to wait for the things to heat up and you need to watch the temperature has gone up to the right temperature before you proceeding into production. The safety side for the induction sealing is no direct heat so there is little chance for heat related injuries. No cutting tools to maintain for traditional induction sealing, while there are four capless induction sealing.

Material Ordering Volume

Regarding custom print on your material, lower volume are often easier to get with induction sealing material. By lower volumes, I am saying less than 500,000 pieces worth of material. For ease of use of equipment, for instant start up purposes, the sourcing of materials, I would put in order: convention sealing where the induction material with a seal placed into a cap prior to the induction sealing, then if that is not possible, capless induction sealing, and then finally, heat sealing.

Where the barrier properties are not that important, and cost is a consideration, it always is, you can save up to 1 to 2 cents if you go to heat seal. Just in the material side of things per product. The bigger the opening of the container, the bigger that saving will be. Typically heat seal for containers of 70mm or 3 inches approximately diameter can present significant material savings.

The SealerOn website shows both heat sealing and induction sealing with an emphasis on induction sealing.

 

Labeling Machine Price Inquiries – How Much?

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Nearly every day, we receive inquiries that we cater through the chat engines on our websites. Many inquiries come from start up businesses trying to figure out the best way to present their products on the market; and what labeling options are available to them.

Have you ever been responsible for labeling a product by hand? If yes, then you know all too well that there is nothing simple about it. You will be curious to know the price of automation and if this is something that can be achieved with the use of smaller machines for starters. With a seemingly endless number of labeling machines to choose from, picking the right labeler for your product can be overwhelming.

Perhaps the most anticipated question customers ask with every chat is “How much”.  How much is the price of our labeling machine? Ask yourself, Is this asking the right question?

A good labeling company will take the time to learn about your specific requirement, your packaging and product, production volume and budget in order to determine the best type of product labeler for your specific application. Let us determine if this is the right time for you to own a self adhesive labeling system.

ROI on Labeling Machine

Labeling Machine ROI Sample ComputationSample Computation Only

The above image shows an example calculation of the cost benefit for changing from the current method of labeling to the proposed Labeler Machine.  You may be hand applying, using a label dispenser, using a benchtop label applicator or using another troublesome or slow in-line labeling machine.

The people at LabelOn™ can assist with a computation to suit your circumstances. Most large companies are looking for an ROI of 4 years or under. Any ROI lower than a year is outstanding and indicates you are very late in making your decision to get a labeling machine.

Choosing the Right Label Applicator

Picking the right labeler for your product can be overwhelming with a seemingly endless number of labeling machines to choose from. The LabelOn™ range can help simplify this because is divided into 4 simple categories, each one representing a specific labeling range capacity.

LabelOn™ Bench-Top Hand Crank Round - Made in the USA

Note: For Android phones that cannot play the video,
Click Here to play the You Tube Version

How would you feel about your product on a shelf with skewed label? There are ways to ensure that this does not happen. Major decisions are made to ensure that the packaging quality is indicative of the product itself, because the saleability of your product often comes down to appeal on a shelf. No one wants to see their product hit the consumer market with an appearance that does not reflect their commitment to quality. So please, ask yourself once again, how much is it worth to you to have your own labeling machine?

Let’s chat. We can help you.