Induction sealing creates a visible seal that assures consumers of the product’s safety. If you package tablets or capsules in bottles, induction sealing may give you an advantage in the industry and provide added assurance to your clients. This article discusses induction sealing components, selection, and installation.
Understanding Induction Sealing
Induction sealing is a non-contact heating process that welds a foil laminate, known as an inner seal, to the lip of jars and bottles. This process occurs after the container has been filled and capped.
As the sealed bottles pass under an induction sealer on the conveyor, an electromagnetic field heats the foil, melting the polymer coating on the induction sealing foil. This creates a hermetic, air-tight seal that offers tamper evidence, prevents leakage, and protects the product from external contaminants. In some cases, the inner seal also extends shelf life.
Key Components of an Induction Sealer
The two major components of an induction sealer are the power supply and the sealing coil.
- Power Supply: This component transforms input power into the necessary power and frequency to seal bottles. The kilowatt (kW) rating of the power supply indicates its suitability for specific applications. Generally, higher line speeds and larger bottle openings require higher kW ratings. For instance, manual or handheld systems may require as little as 0.5 kW, while high-speed lines might need up to 6 kW. Pillar Technologies offers a range of induction sealers for bottles, including the flagship iFoiler™ Induction Sealer, which provides unmatched cap sealing efficiency and a responsive touchscreen interface.
- Sealing Coil: The sealing coil, a metal conductor surrounded by ferrites and enclosed in a non-conductive housing, directs and focuses the electromagnetic field for sealing efficiency. Two basic designs are prevalent: flat coils and tunnel (or channel) coils. Flat coils are suitable for standard flat caps ranging from 20 to 120 millimeters in diameter, while tunnel coils are used with spouted or dispensing caps. Pillar Technologies offers additional induction sealing coils, such as the Universal Sealing Coil, allowing for flexibility in sealing various cap styles.
Waterless (Air-Cooled) vs. Water-Cooled Systems
Modern induction sealers have transitioned from water-cooled to waterless (air-cooled) systems. Air-cooled sealers are more compact, eliminating the need for water recirculation, filtration systems, hoses, radiators, pumps, and flow switches. This shift results in reduced maintenance, enhanced reliability, and lower operational costs.
Induction Sealers vs. Heat Sealers
When choosing between induction sealing and traditional heat sealing methods, it's essential to understand their differences:
- Induction Sealing: This non-contact process uses electromagnetic induction to heat a foil laminate, creating a hermetic seal. It offers benefits such as tamper evidence, leak prevention, freshness retention, and protection against package pilferage.
- Heat Sealing: This method requires direct contact between a heated element and the sealing surface. While effective, it may not provide the same level of tamper evidence or protection as induction sealing.
Should My Business Invest In An Induction Sealer?
When evaluating the purchase of an induction sealer, consider whether adding an inner seal will improve your packaging quality and product safety. If the answer is yes, the next step is comparing different models to ensure you select the best option for your needs.
Comparing Induction Sealers
If you’ve decided an inner seal is beneficial, you’ll want to compare induction sealers next. Start by considering the service life you can expect from the machine and the quality of service you can expect from the supplier.
- Evaluate Expected Service Life: Look at the sealer’s electronics, which typically dictate its life expectancy. Induction sealers are manufactured to last a long time. In fact, some sealers in daily use today are more than 25 years old. However, the availability of the electronics used to build the equipment is always a factor. As electronics are upgraded, replacement parts are harder to find. Reputable manufacturers design equipment based on components that they can replace for years to come.
- Flexibility and Scalability: Your induction sealer should accommodate various cap and bottle sizes. Opting for a system that supports interchangeable sealing coils without tools can save time and costs as your packaging needs evolve.
- Cost Considerations: While upfront cost is important, factor in long-term expenses such as maintenance, service availability, and potential repairs. Be cautious with used equipment, as outdated technology and lack of service support could lead to hidden costs. Always verify a used machine’s age, condition, and serviceability with the manufacturer before purchasing.
- Consider Long-Term Costs: Consider long-term costs and future maintenance. Investing in a higher-quality system now may reduce downtime and service expenses in the future, and some systems may require more regular maintenance.
Pro Tip: When comparing price quotes, make sure you're evaluating systems with the same power supply size, coil design, and mounting arrangements. Differences in these components can affect pricing and performance.
Optional Equipment and Features
To enhance the functionality of induction sealers, consider optional equipment such as:
- Seal-Integrity Detectors: These devices detect missing foil, loose caps, misaligned caps, and stalled bottles, ensuring quality control.
- Pneumatic Reject Devices: Working in tandem with seal-integrity detectors, these systems eject potentially unsealed products, preventing faulty seals from reaching consumers.
- Visible or Audible Alarms: These alerts notify operators of issues, even from a distance, facilitating prompt corrective actions.
- Validation Support: Installation Qualification (IQ) and Operational Qualification (OQ) are becoming standard in pharmaceutical, dietary supplement, and food industries, ensuring compliance and consistency in sealing processes.
Installation Considerations
Installing an induction sealer is straightforward, typically requiring 3 to 5 feet of straight, unimpeded conveyor space for mounting the sealing coil. The coil should be mounted parallel to the conveyor, and the sealing zone must be free of metal components to prevent accidental heating. Pillar Technologies provides comprehensive installation support to ensure seamless integration into existing production lines.
Work with the Experts at Pillar Technologies
Choosing the right induction sealing system can feel overwhelming, but you don’t have to navigate the process alone. At Pillar Technologies, our team of experts is here to help you make the best choice for your specific needs. Whether you're looking for guidance on selecting the right power supply, coil design, or optional features, we make it easy to find the perfect solution for your production line.
With decades of industry experience and a commitment to exceptional customer support, we ensure that your sealing system is optimized for efficiency, reliability, and long-term success. Contact us today to discuss your project and let our experts guide you to the best induction sealing solution for your business.