Customer challenge
A leading manufacturer of packaging machines was looking for an innovative solution to make packaging for the food industry more sustainable and efficient. In this industry, the packaging must meet strict requirements in terms of hygiene, stability and environmental friendliness. The quality of the bond between the paper tray and the plastic wrap is particularly important.
The previously used permanent heating system revealed several weaknesses, which is why the customer needed a more precise and efficient sealing solution that would ensure a consistently high-quality bond without damaging the cardboard or causing burns. At the same time, the new tool needed to be identical in size to the existing system, but offer better temperature control and more efficient heat distribution.
Our solution
To meet the customer’s requirements, we developed a customized solution involving a precisely adapted heat-sealing band geometry with a diameter of less than 15 mm. Working closely with the customer, we quickly developed a prototype that we continued to refine. The result was an innovative sealing tool with impressive technical features.
The tool housing was manufactured using 3D printing, which ensured a high level of integration with compact dimensions. We also developed a wiring harness that allowed flexible expandability by adding different numbers of welding elements. This modularity offers the customer high flexibility and scalability. The entire system was based on RESISTRON technology, which guarantees precise and fast control of the welding temperatures.
The integration of the extensive technology in a very small space was particularly impressive. One member of the project team emphasized the innovative character of the solution: “There was no blueprint—together we created something completely new that can now serve as a standard in the industry.”
Customer benefit
Thanks to precise controls, the temperature remains constant at all sealing points, which significantly reduces the risk of burns on the carton. The result is uniform, small sealing areas that ensure a secure and aesthetically pleasing closure. In addition, the lower heat development of the heat-sealing tape reduces energy consumption and extends the service life of the tool.
These advantages not only make the new welding tool attractive for existing customers, but also offer considerable potential for new customers who face similar challenges in the food industry.
Customised heat-sealing tool:
